Are low-silica surfaces the answer to artificial stone fears?
With no- or low- silica surfaces hitting the market in response to silicosis concerns, how far do they go to fix the problem? And are they really likely to replace high-silica surfaces going forwards? George Dean reports…
Unless you’ve been living under a rock, you’ve likely heard about the ongoing discussion over engineered stone surfaces.
The biggest headline in this ongoing story was Australia’s ruling that it would ban high-silica products from its market from July of this year, in an effort to curb what some critics have described as a silicosis “epidemic”.
Silicosis is a disease which is currently believed to be incurable, with symptoms including shortness of breath, coughing, pneumonia or tuberculosis. It’s not a new disease by any means – cases have been around for thousands of years, in fact – but in the last few decades, research has linked it to stonemasons, which in terms of the KBB market, means worktop fabricators can be at risk if proper safety regulations aren’t followed.
The biggest risk of silicosis for fabricators comes when they cut into the products and silica dust is released. Although, this doesn’t mean the products themselves are inherently dangerous. Responding to Australia’s decision, the Worktop Fabricator’s Federation (WFF) in the UK has reassured those concerned that there “is no health risk in handling, shipping, installing or using engineered stone worktops”, and that the risk of respirable silica dust is “purely to do with factory management in the fabrication process”.
Now, looking to make these products even safer, the major surface suppliers have come up with a solution: reducing the risk of silicosis by significantly decreasing, or in some cases, removing entirely, the silica content that can cause health problems.
Surface issues
Earlier this year, Caesarstone released new Mineral surfaces, a range of low-silica products designed as an alternative to the brand’s existing portfolio. Edward Smith, MD of Caesarstone UK and ROI said the collection “represents another key milestone in [the company’s] journey”, adding, “With the introduction of our Mineral Surfaces, we are proud to offer a low-silica option that not only meets our stringent sustainability standards but also upholds the high performance and durability expected from Caesarstone surfaces.”
Similarly, 2024 will also see the launch of Neolith’s crystalline silica-free product line known as Neolith for a New Era. Announcing the product, Neolith’s CEO, Jesús Ayarza, said “These new crystalline silica-free products have the same technical characteristics our customers so adore. We truly believe marble workers and installers will be impressed by how you can work with them.”
Ross Stewart, senior sales manager for Neolith UK adds: “Our new silica-free product line is a reflection on our deep-rooted commitment to environmental responsibility and advancing industry standards, while prioritising safety and well-being by taking care of the entire value chain, including those involved in the process of handling and manufacturing our surfaces.”
Another company making strides with engineered stone surfaces is Cullifords, which has updated its core range of Carrara quartz to now have less than 1% silica content. Cullifords director Oli Webb says this is so that customers can have more options, adding: “We have always promoted natural stone, which in general, has significantly less silica than man-made quartz. Sapienstone Ceramics are another option for our customers to switch away from quartz if they choose to.”
Cosentino is similarly launching its Silestone XM surfaces this year, which are said to contain a minimum crystalline silica content of 10%.
According to Katy Parry-Stone, retail expert for Cosentino UK: “Silestone XM is manufactured using the innovative Silestone HybriQ+ technology meaning it is engineered with a minimum of 20% recycled materials, 100% renewable energy and 99% recycled water and zero discharge.”
So, how do low-silica surfaces stack up against their higher-silica counterparts? According to Jonathan Stanley, vice president of marketing at Caesarstone UK, the products contain all the same material ingredients, but in vastly different ratios.
“From our perspective, there’s a lot more feldspar that goes into the products,” Stanley says, adding, “And it is also an opportunity to some degree to try and incorporate more in the way of recycled materials as well.”
And, according to Stanley, despite the low-silica make up of Caesarstone’s new Time products, the current Health and Safety Executive (HSE) guidelines are still expected to be followed.
Andy Philips, director at the WFF, advises: “Regardless of the material’s silica content, fabricators must invest in effective machinery including water suppressed cutting, local exhaust ventilation, and wear necessary PPE to demonstrably control the dust generated.”
What’s next?
So, with these revolutionary new products either on the way or here already, is it reasonable to expect to see all engineered surfaces going the way of low- or no- silica? Caesarstone’s Stanley seems to think so.
“I think that’s Caesarstone’s long-term path,” he says. “There are some people that are starting to talk to us about it in the UK, but I don’t think the concern is as big here as it is in other markets. However, as a global company, obviously we look at our whole product portfolio when considering how we approach things.”
It’s important to note that Stanley also believes education on safe practice is just as important as material composition.
“It’s very much a question of educating the market, educating the fabricators, and educating the retailers about what they’re buying as well as how it’s being fabricated,” he says. “We are on a path to low or zero silica. And that will be driven by the speed with which we can innovate.”
Ross Williamson, sales director at The Surface Collection agrees that low-silica quartz products are the future for the industry, but believes that retailers should keep an eye on developments and innovations from suppliers to make sure they’re investing in the right products.
Speaking on a panel about the surface market at InstallerSHOW, he explained: “When it comes to new emerging products, the ones that cost slightly more have no doubt got more research and development behind them. I’m hearing that cheap no- or low- silica quartz isn’t always a good long-term idea, because some suppliers are likely using the wrong type of glass in its composition. They’re saving a few pounds by using a cheaper glass, but when you fabricate it, the glass pulls out.
“Also, with the increase in resin in these products, in some cases they can actually fade a lot quicker. Again, don’t go for a cheap emerging product – that’s never a good idea. The difference isn’t that much when you’re talking about a whole kitchen.”
Despite an increased focus on protective standards, some retailers argue that they would still prefer to have high-silica products simply taken off the market entirely. A particularly vocal proponent of this course of action is Herringbone, a Kent-based retailer which made headlines earlier this year for its decision to ban the sale of high-silica worktops entirely.
Writing in the August issue of kbbreview, director William Durrant says: “The risk of this material is not necessary when there are so many beautiful alternatives on the market”. However, he welcomed the introduction of low-silica engineered quartz, saying it “can look exactly the same as high silica, and the look is not different for the consumer.”
However, despite there currently being no plans to do so in the UK, Durrant also believes that high-silica stone will eventually be banned from the market. “Manufacturers are aware that there is only one direction this product will go,” he says, “Be it tomorrow or in five years’ time, it will eventually be off the market due to the health risks. What they hope is that they can sell off their stock of high-silica engineered stone before the ban comes into place and then invest in the low-silica options then.
“While there will always be a level of silica used within the manufacturing industry that are harmful, it would be very easy for the UK to ban this product that is seen as the leading cause of silicosis. There are so many beautiful alternatives available. The end result would be better for everyone in the supply chain for generations to come.”
History repeats
So, are we genuinely likely to see engineered surfaces banned in the UK? Looking at the history, it’s not very likely.
Some media outlets have drawn comparisons between the engineered stone issue and other materials-based health concerns in the past. In December 2023, the Daily Mail referred to engineered stone as “the modern-day asbestos”. Others have compared silica surfaces to what happened with medium-density fibreboard (MDF) in the 1990s.
MDF was commonly used in furniture at the time, and consists of wood dust and scrap materials bonded together by a resin containing formaldehyde – a known carcinogen. When the product is cut or sanded, dust particles containing formaldehyde are released into the environment, posing a health risk to anyone that inhales them.
In a landmark Guardian article published in 1997, the newspaper referred to the product as “the asbestos of the Nineties” and wrote about how trade unions were calling out for the government to act on the product in the name of health and safety. Sound familiar?
Caesarstone’s Jonathan Stanley also draws a comparison between silica surfaces and MDF, but notes: “I suppose the one major difference with the MDF story is that stone is being cut by professionals, so when they do it properly, it’s safe. MDF was being bought in massive sheets and we were all using it at home. But these days, MDF is still around.”
Despite the MDF scare in the 90s, the material is considered safe for use today thanks to a combination of manufacturers severely reducing the quantities of dangerous materials in their make-up, and also the HSE and trade bodies advocating for greater safety standards when working with the product. These are both strategies that are also being used in response to engineered stone.
In the present day, we know that UK government ministers are aware of the silica surface issue and are keeping their eyes on it. In January of this year, a Parliamentary debate on the topic of engineered stone in the UK was raised in response to the ruling in Australia. Although briefly discussed, the idea of a ban was swiftly dropped. Ministers opposing the ban argued that the HSE had done much work to promote the safety of techniques such as dry cutting, and assured the other ministers that campaigns to raise awareness would certainly continue.
So with a total ban looking unlikely, the industry’s suppliers have committed to continue working with groups like the WFF and HSE to innovate and make their products as safe as possible, while still advocating for proper health and safety for stonemasons and fabricators.
Caesarstone’s Jonathan Stanley believes that it’s not so much a question of if the industry starts pursuing low or no silica surfaces, but when, concluding: “We are transitioning to a complete low silica product range. It’s just a question of how quickly we can get there.”