Alternatives to Engineered Stone: A Guide for Designers & Consumers

Engineered stone has become a popular option for the design industry as a selection for benchtops in kitchens and bathrooms particularly, due to its durability and low maintenance, but it has a major flaw – it contains Crystalline Silica.

Why this is so dangerous?
It’s important to emphasise that once products are installed, they are not a danger to health. However, when safety measures are not followed during the processing of high-silica content products, it can pose serious risks to stone masons and other workers who handle silica. Even with safety measures and equipment, high silica content products can still be a risk to workers' health.
Inhaling Crystalline Silica dust can cause permanent lung damage, this can lead to the incurable silicosis and other respiratory diseases that are progressive, debilitating and sometimes fatal.

Where does this effect workers?
Silica dust is produced during various workplace processes like cutting, drilling, polishing or sanding of natural or engineered stone, bricks, tiles or other products containing silica. Some of the main industries where workers are exposed to silica dust;

• Construction sites: Workers who work with concrete or masonry.
• Mining operations: Workers in mining ops, such as coal and metal mining, may be exposed during drilling, blasting and crushing processes.
• Sandblasting facilities: May be exposed to high levels of silica dust during the sandblasting process.
• Stone or rock quarries: Workers in quarries that mine, process stone or rock are at risk of inhaling silica dust during cutting, grinding or polishing.
• Manufacturing facilities: Workers in manufacturing facilities that produce products containing silica, such as glass, ceramics or refractory materials.

What’s happening now?
The issue of silica dust is not new to the design industry and measures have been implemented over the years to mitigate its impact. Despite these efforts, it seems that more needs to be done, as the Australian government is now considering a ban on the material by the end of 2024.
This move comes in response to a warning issued by the construction union in late 2023, which called for a ban on the use, manufacturing and importation of engineered stone by July 2024.

What can we do as a designer or consumer?
If you’re planning a new build or renovation there are many other low or no silica options which still have many advantages as engineered stone.

A few of these options include;

1. Corian solid surfaces, which are made from a blend of acrylic and natural minerals (zero silica).
2. Porcelain slabs, which are made from clay and other natural minerals and can be used for countertops, splashbacks, flooring and more.
3. Natural stone, marble and limestone particularly contain approximately 2% silica (according to safe work Australia).
4. Terrazzo, is a composite material made from chips of natural stone, glass, and other materials, bound together with cement or epoxy.
5. Laminate, which is made from layers of paper or fabric that are infused with resins and bonded together under high heat and pressure.
6. Other low or no silica alternatives; timber, stainless steel, concrete, sintered stone (such as Lapitec) and ceramic tiles.

It's important to note that some of these alternatives may still contain some level of silica, but they are generally considered to be much safer than engineered stone being up to 97% silica (according to safe work Australia).
Certain manufacturers of engineered stone, such as Smartstone and Caesarstone, are taking on the responsibility of developing low-silica content alternatives. With varying levels of silica present in different types of engineered stone, it is crucial to specify consciously and encourage the demand for low-silica options, similar to natural stones.

It is uncertain whether a resolution to this issue will be reached soon, but it is promising that more people are becoming aware of the potential hazards associated with this material.

Knowledge is power and we hope that through this blog post you have gained a better understanding of the concerns surrounding silica dust exposure and why the Australian government is considering a ban. We hope you are now familiar with some of the alternative materials available for consideration for any upcoming projects.

^{Reference list: Safe Work Australia. "Crystalline Silica and Silicosis." Accessed 18.05.2023. Available at: (https://www.safeworkaustralia.gov.au/safety-topic/hazards/crystalline-silica-and-silicosis)}