Safety Health and Environmental Services

Scientists Pinpoint Hazards for Engineered Stone Fabrication Shop Workers

admin — Mon, 28 Jul 2025 18:23:41 +0000

Scientists Pinpoint Hazards for Engineered Stone Fabrication Shop Workers admin Mon, 07/28/2025 - 14:23

You've probably seen fabricated stone countertops on an HGTV remodeling show — and you might even have them in your own home.

The durable, affordable, and highly customizable product debuted in Italy in the 1970s and continues to grow in popularity. Between 2010 and 2018, U.S. imports of engineered stone slabs increased by 800%. One report predicted that global demand will increase 5.4% each year, to reach 97 million square meters by 2028.

Sometimes referred to as manufactured stone or quartz (which is, confusingly, also the name of one of its main components), to the untrained eye, the material looks no different from natural stone. One of its biggest advantages is that it can be made to resemble marble, granite, or nearly any other stone.

Beneath the material’s familiar smooth surface, however, lie safety risks for engineered stone workers.

Research conducted by a team of Georgia Tech scientists demonstrates that everyone in a fabrication shop is at risk, not just the workers cutting and fashioning the material.

The group included members of the Enterprise Innovation Institute’s Safety, Health, and Environmental Services (SHES) program: Jenny Houlroyd, Hilarie Warren, Brandon J. Philpot, and Sean Castillo. Together with Jhy-Charm Soo of Georgia Southern University, they recently published their findings in Oxford Academic.

The study divided engineered stone workers into four risk groups and charted their relative exposure to the material’s chief hazard: respirable crystalline silica.

A “Toxic Product”

Engineered stone differs notably from its natural counterpart, both in composition and in danger to worker health.

A stone slab cut from the ground, such as granite or marble, comprises several different minerals and typically has a concentration of 40% or less of mineral crystalline silica — usually quartz, which is the most abundant form of crystalline silica.

Engineered stone, however, can contain more than 90% silica. Slabs are produced when silica is crushed, combined with synthetic resins, and compressed using heat or pressure.

During fabrication, these slabs are cut and shaped by powered hand tools. The resulting dust contains tiny particles of respirable crystalline silica. Once inhaled, some of the particulate may stay in the lungs and cause an inflammatory response.

While crystalline silica is released from both natural and engineered slabs during fabrication, the engineered slabs’ significantly higher percentage of silica poses a much greater risk to human health.

A growing body of research indicates that breathing engineered stone dust leads to lung inflammation and can cause acute silicosis, an untreatable lung disease.

“I would classify engineered stone as a really toxic product,” said Houlroyd, manager of occupational health services at SHES. “When you have something that’s high-risk, you have to prepare for systems to fail and have backup measures.”

Committed to Safety

Over six years, the SHES research group collected air-sampling data, making 17 visits to 11 Georgia stone fabrication shops. The shops had all requested air-sampling services offered by SHES.

“The companies agree that by working with us, they commit to correcting the hazards and reducing exposures, as much as is feasible,” Houlroyd noted.

Because most kitchen and bathroom countertop fabrication shops are small employers, workers often complete a variety of tasks, resulting in a range of exposure factors.

The research team recommended that all manufactured stone fabrication workers wear respirators, such as an N95 mask. For employees who are the most exposed, they recommended a respirator with a powered air-purifying element or supplied air.

But personal protective equipment (PPE) alone does not ensure safe conditions.

“Most of the workers in this industry are relying on respirators as their primary source of protection, and they need a lot more to protect them,” explained Houlroyd. “PPE is the last line of defense, and safety needs to be addressed from all angles.”

Part of that multifaceted strategy includes repeated monitoring of air quality and equipment. It’s also crucial for employers to make sure that exposure risks are understood by all workers — not just employees, but also contract and day laborers, as well as those working for cash.

More Than Just a Job

As members of SHES, the Georgia Tech research team members are first and foremost health and safety consultants, with expertise spanning industrial hygiene, environmental compliance, and Occupational Safety and Health Administration (OSHA) regulations.

For Houlroyd, worker safety is not just a professional calling; it’s also a personal mission.

“My dad got sick with brain cancer from exposure to contaminants on the job, and he died four years ago,” she said.

“Though he didn’t work in the manufactured stone industry, his story is representative of many people who go to work each day to feed their family, are not aware of workplace hazards, and then find themselves sick.”

The public can play a part in worker safety, too.

“Consumers have a choice and can educate themselves about what type of countertop materials they choose to have installed — like how we look at food labels for nutritional information,” said Warren, who oversees the OSHA Training Institute Education Center at Georgia Tech.

“We should be aware of the risk to workers, as well as how the installation process in our homes should be properly managed to prevent dust contamination,” she added.

A Zero-Risk Solution

In 2024, Australia eliminated the risks associated with engineered stone fabrication. Despite having enacted stronger regulations in 2019, the country continued to see a rise in silicosis cases resulting from exposure to respirable crystalline silica.

Australia’s solution? Enacting a ban on the import and fabrication of the material until its safe manufacture can be demonstrated.

In their report, the Georgia Tech group recommends that the U.S. do the same. As Houlroyd put it, “I would love to see our country find a safer substitution and take this dangerous product off the market.”

____________________

Title: “Respirable dust and respirable crystalline silica exposures among workers at stone countertop fabrication shops in Georgia from 2017 through 2023”

Conflict of interest: Jenny Houlroyd has served as an expert witness in silicosis legal cases unrelated to this research. All other authors declare no conflict of interest.

Funding: The U.S. Department of Labor, Occupational Safety and Health Administration (OSHA) as part of the OSHA 21(d) Consultation Program grant.

DOI: https://academic.oup.com/annweh/advance-article/doi/10.1093/annweh/wxaf014/8116008?utm_source=advanceaccess&utm_campaign=annweh&utm_medium=email

Summary sentence

Engineered stone has been in use for homes since the 1970s but creates serious health hazards for workers who produce them.

Summary

Australia enacted a ban on the import and fabrication of manufactured stone slabs because of health hazard concerns. Researchers from Georgia Tech and Georgia Southern University recommend the U.S. do the same.

Dateline

Mon, 07/28/2025 - 12:00

eve.tolpa@innovate.gatech.edu

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Eve Tolpa
eve.tolpa@innovate.gatech.edu

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SHES Collaborates with University of California San Francisco to Assess Pork and Poultry Worker Safety

admin — Wed, 16 Apr 2025 14:45:41 +0000

SHES Collaborates with University of California San Francisco to Assess Pork and Poultry Worker Safety admin Wed, 04/16/2025 - 10:45

ATLANTA and SAN FRANCISCO — When University of California San Francisco (UCSF) officials were contracted by the U.S. Department of Agriculture (USDA) to conduct research on line speeds at pork and poultry processing facilities, they knew exactly who to ask for additional support: researchers from the Safety, Health, and Environmental Services (SHES) division at Georgia Tech.

A program housed in Tech’s Enterprise Innovation Institute, SHES offers occupational safety, health, and environmental (OSHA) consulting and training services to manufacturers across the country and has worked extensively examining food-processing workers’ exposure to chemicals.

UCSF needed a partner with specific scientific expertise regarding employee exposure to a chemical used to limit bacterial growth during pork processing. SHES’ prior working relationship with UCSF also proved beneficial. In 2021, SHES industrial hygienist Brandon Philpot was the primary investigator (PI) for a collaborative project with a group from the UC system to develop safety training for workers fabricating engineered stone countertops.

“UC San Francisco’s School of Medicine was so impressed with our team's work, they came back to us for this much larger project,” said Jenny Houlroyd, Ph.D., manager of occupational health services at SHES. “We're trying to build meaningful relationships and leverage expertise across institutions.”

Study Parameters

The study was initiated when the USDA’s Food Safety and Inspection Service division contracted with third-party experts to investigate whether increases in poultry and swine evisceration line speeds affected worker safety.

A secondary aspect of the study looked at the potential for an increase in worker exposure to peracetic acid (a food-safe chemical applied to surfaces in certain food-processing applications) when processing line speeds are increased.

“The study’s designers believed that ergonomics was the driving factor in worker safety, but they were unsure if by slaughtering and processing more animals per day, workers were also applying more peracetic acid,” said Houlroyd. “This is what the SHES team was asked to measure.”

In addition to tapping Georgia Tech’s expertise in industrial hygiene, UCSF brought in several other schools in the University of California system, primarily UC Berkeley, to assist with research.

Scope of SHES’ Role

“Our work with UC started in July 2024 and was completed in January 2025,” said Houlroyd, who served as the project’s PI and UC liaison.

Conducting the field research were SHES industrial hygienists Philpot, Sean Castillo, and Bob Hendry, as well as SHES OSHA Training Institute Education Center manager Hilarie Warren. The group traveled to six pork processing plants across the U.S. over 11 weeks.

Although the preferred method for industrial hygiene and worker exposure is to chart direct exposure to the workers themselves, the study did not allow employees to wear chemical monitors on the processing line for safety reasons.

“Our on-site sampling included putting on a variety of wearable monitors on ourselves,” Hendry said. “We’d then go to the various work areas in the plant where peracetic acid was used, stand next to the workers, and take readings.”

Each SHES team member upheld consistent sampling standards, but they were stationed at different sites. As a result, Castillo said, “It was up to us to use professional judgment to evaluate where the areas of concern were. We had to make sure we were very organized so that if I was at one site one week and Bob came out the next week, we could replicate our data almost one-to-one.”

Importance of Worker Interviews

The USDA study received Institutional Review Board (IRB) approval, which is needed if researchers interact with human subjects. Houlroyd noted that because the USDA study was considered formal research, IRB approval was necessary.

Although conducting worker interviews was not a requirement of their participation, the SHES team set up a special room where they interviewed employees on ergonomic issues and musculoskeletal disorders.

“We were able to take the load off from our collaborators and, in doing so, speed up their process so that they could finish their research earlier,” said Castillo.

Philpot stressed the importance of worker interviews to the study. “The process was good for collecting background information on what the employees were going through, day in and day out, to see if there’s anything that we could do to help their situation.”

By putting workers at ease, he and his teammates were able to gain their trust and listen to their concerns. “They could actually see that we cared about what's going on,” Philpot said.

According to Houlroyd, “One of the reasons the UC group loved Brandon and Sean and Bob so much is that we've had so much experience doing interviews, we were quick to jump into that role and help them. Our team knows that there is dignity in all labor, so we approach workers with respect. We meet the workers where they are, and we speak to them not as an academic, but human to human.”

Study Results

Acting Secretary of Labor Julie Su reported that the USDA study found that faster line speeds did result in an increased risk of injuries, but that this risk “could be mitigated with other controls, specifically having more workers on the line and having effective ergonomic plans.”

The results of the peracetic acid research conducted by SHES, however, were inconclusive. “Was there more exposure at the faster line speed?” asked Houlroyd. “We found one plant where it was true, but it wasn't consistently true at all the plants, so it was determined that there should be more research.”

Regardless, she welcomed the chance to strengthen collaborative ties with the UC system and celebrated the meticulous and compassionate work conducted by SHES.

“I am so grateful for this team for traveling to remote locations in our country and spending 11 weeks in slaughterhouses,” said Houlroyd. “I had no doubt that we could do it, and we did it well.”

Summary sentence

The group traveled to six pork processing plants over 11 weeks.

Summary

The project was designed to optimize worker safety.

Dateline

Wed, 04/16/2025 - 12:00

etolpa3@gatech.edu

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Eve Tolpa
etolpa3@gatech.edu

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Scientists Pinpoint Hazards for Engineered Stone Fabrication Shop Workers

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SHES Collaborates with University of California San Francisco to Assess Pork and Poultry Worker Safety

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