Safety & Compliance · SOP

Silica Dust Awareness For Corian Solid Surface Fabrication

This SOP outlines the required engineering controls, respiratory protection, and safe work practices to minimize exposure to respirable crystalline silica (RCS) during cutting, grinding, and finishing of solid surface materials such as Corian in a fabrication shop environment.

Estimated Time

30 min

Difficulty

Intermediate

Regulation

WorkSafeBC / CSA Z94.3-07

Version

1.0

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Purpose

The purpose of this SOP is to ensure that all personnel involved in solid surface fabrication understand the hazards of respirable crystalline silica dust, the methods to control exposure, and the required personal protective equipment (PPE) and training. This document supports compliance with Occupational Safety and Health regulations including WorkSafeBC's silica exposure control plans.

Scope

This procedure applies to all fabrication activities involving Corian and similar acrylic solid surface materials that generate airborne dust during cutting, routing, sanding, polishing, and grinding. It also covers housekeeping and waste disposal of silica‑contaminated debris. All shop employees, contractors, and temporary workers must follow this SOP.

Safety Precautions

ENG Do not proceed without functioning local exhaust ventilation (LEV) verified by a pre‑shift check. Use wet methods whenever possible to suppress dust at the source.
RESP A fit‑tested N95 respirator (or higher, based on exposure monitoring) must be worn at all times in the work zone. No facial hair that interferes with the seal is permitted.
HOUSE Never use compressed air to clean dust from surfaces or clothing. Use HEPA vacuuming and wet‑wiping only. Accumulated dust must be removed daily.
ZONE Erect impermeable barriers around the work area to prevent dust migration to adjacent workstations. Post warning signs at all entrances to the dust‑control zone.

Required Tools & Materials

Local exhaust ventilation (LEV) system with HEPA filtration (minimum 99.97% efficiency at 0.3 µm)
Wet‑cutting saw or water spray attachment for grinders
HEPA‑rated vacuum (class H) with grounded hose
NIOSH‑approved respirators (N95 or P100) with fit‑test records
Personal air monitoring pump with cyclone (e.g., SKC or equivalent)
Impermeable plastic sheeting and tape for zone isolation
Warning signs: "Silica Dust Hazard – Respirator Required"
Disposable coveralls, safety glasses, and work gloves

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Procedure: Step-by-Step

1 Conduct Job Hazard Analysis (JHA): Identify all tasks that may generate airborne silica dust (cutting, sanding, routing, polishing). Review the SDS for the Corian material – note that Corian itself does not contain crystalline silica, but operations on adjacent materials or from joint compounds may introduce silica. Document the JHA and sign off.

2 Implement Engineering Controls: Activate and verify LEV system – do a pre‑shift check using a manometer or flow hood. Ensure capture velocity > 1 m/s at the source. Apply water spray to cutting blades or grinding wheels when possible to suppress dust. Seal off adjacent work areas with impermeable barriers.

3 Select and Use Respiratory Protection: Based on the most recent air monitoring results, assign a respirator. For exposure ≤ 10× OEL, an N95 is sufficient. For higher levels, use a half‑face or full‑face respirator with P100 filters. Perform a fit test for each wearer and document. Do not exceed the assigned protection factor.

4 Establish Housekeeping and Waste Disposal: During the shift, use HEPA vacuum to remove dust from surfaces every 2 hours. At end of shift, wet‑wipe all surfaces. Do not sweep dry. Seal all dust waste in labelled bags (e.g., "Silica Dust – Hazardous Waste") and dispose of per local regulations.

5 Perform Personal Air Monitoring: At least quarterly, collect personal breathing zone samples using a sampling pump (1.7 L/min) with a Dorr‑Oliver cyclone. Send to an accredited laboratory for analysis per NIOSH Method 7500. Keep records for at least 30 years. Review results and adjust controls if > 50% of the exposure limit is reached.

Silica Dust Awareness For Corian Solid Surface Fabrication

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