The Silicosis Crisis: Engineered Stone Under Scrutiny

A surge in cases of silicosis, an irreversible and potentially fatal lung disease, among workers who fabricate engineered stone countertops has prompted regulatory, legal, and legislative debates across the United States. California is currently considering a ban on cutting high-silica quartz material, while a proposed federal bill seeks to shield manufacturers from worker lawsuits.

Scope of the Health Crisis

Since 2019, California health authorities have identified over 500 confirmed cases of silicosis linked to engineered stone fabrication. State public health officials reported that among these cases:

• More than 50 workers have required lung transplants
• At least 29 have died
• Median age at diagnosis: 46
• Median age at death: 49

Most affected workers are Hispanic men, often in their 30s or 40s.

"State public health officials estimated in 2023 that up to 850 of California's estimated 4,000 stone fabrication workers could develop silicosis, with potentially 160 fatalities."

Experts have stated that underdiagnosis is likely, suggesting the actual number of cases is higher.

National Impact

Since 2023, OSHA has inspected over 400 countertop workplaces across at least 25 states, covering over 7,500 workers. The findings are alarming:

• About 20% of air samples exceeded the permissible exposure limit for silica
• 33% exceeded the action level
• Over 75 citations were issued for a lack of medical surveillance

Cases have been reported in states including Texas, New York, Colorado, Florida, Washington, and Massachusetts.

The Disease and Material

Silicosis is caused by inhaling crystalline silica dust, which leads to inflammation and scarring of the lungs, impairing oxygen absorption.

Engineered stone, also known as quartz, is typically made from crushed quartz bound with resins. It can contain up to 95% crystalline silica. By contrast, natural stone such as granite or marble contains between 3% and 30% silica.

"Workers have developed the disease after as little as two years of exposure."

Power tools used to cut, grind, and polish engineered stone generate fine respirable silica dust that can lodge deep in the lungs.

Proposed California Ban

On May 21, California's Occupational Safety and Health Standards Board is scheduled to vote on a petition from the Western Occupational & Environmental Medical Association (WOEMA) to ban the cutting of high-silica engineered stone.

WOEMA president Dr. Robert Blink stated that the number of new serious illnesses and deaths is unacceptable and noted that researchers have measured unsafe silica levels even in shops with dust controls.

California's workplace health regulator, Cal/OSHA, implemented temporary emergency rules in late 2023 requiring respirator masks and wet processing for certain tasks. However, low compliance has been reported among small and medium-sized fabrication shops.

"Alice Berliner, director of the Office of Worker Health & Safety for the Los Angeles County Department of Public Health, reported that her team observed no workers wearing appropriate respiratory protection in over a hundred visited shops, and estimated that at least 25% of shops continue to dry-cut stone."

National Legislative Action

A bill titled the "Protection of Lawful Commerce in Stone Slab Products Act" has been introduced in Congress. It would largely prohibit workers from filing lawsuits against companies that manufacture and sell raw engineered stone slabs.

Supporters' Arguments

• Cambria, a primary U.S. manufacturer, states its own facilities operate safely using dust control measures, arguing the product is not the issue but rather unsafe cutting processes.
• Gary Talwar of Natural Stone Resources reported that distributors face lawsuits despite not cutting, grinding, or polishing stone, leading to significant defense costs.
• Supporters argue manufacturers should not be liable for injuries resulting from employers' non-compliance with OSHA standards.

Opponents' Arguments

"Dr. David Michaels, a former head of OSHA, stated the bill would remove a key mechanism for driving product reform and called it a 'death sentence for workers.'"

• Attorney Raphael Metzger stated that the stone slabs should be banned because they are deadly and cannot be fabricated safely.
• Rep. Hank Johnson (D-Ga.) questioned why Congress would grant legal immunity to manufacturers and suppliers.

Manufacturer and Industry Responses

Cambria attorney Rebecca Shult has objected to naming engineered stone as uniquely dangerous, stating that any high-silica material requires precautions and that the problem lies with countertop businesses that cut raw slabs without proper protections. The company faces approximately 400 lawsuits from workers employed by other companies.

"Major engineered stone brands, including Caesarstone and Cosentino, are introducing products with lower silica content."

• Caesarstone US has launched products with less than 1% silica
• Cosentino states one-third of its portfolio contains less than 10% crystalline silica

International Precedents

• Australia: In 2024, Australia prohibited the manufacture, supply, and installation of engineered stone containing high levels of crystalline silica after systematic CT-based screening revealed a high prevalence of lung disease in workers.
• Israel: Israeli physicians documented aggressive silicosis in young countertop workers as early as 1997.

Legal Outcomes

In Colorado, a jury awarded damages to former worker Tyler Jordan, who developed silicosis and silica-related kidney failure, finding several companies liable for his illnesses.

More than 370 lawsuits are currently ongoing across the country.