New OSHA Regulations on Silica Exposure: What Workers Need to Know

Silica exposure remains a major health risk in 2025, especially for workers in artificial stone fabrication, construction, and demolition. Inhaling crystalline silica dust can lead to silicosis, lung cancer, and other severe respiratory diseases. While OSHA has established a silica PEL, these are not and have never been safe levels.  Moreover, new research shows that even the best protective measures cannot keep silica levels below the PEL when fabricating artificial stone.  Furthermore, the OSHA silica PEL was developed for natural stone, it is entirely ineffective for artificial stone.

In response to the growing number of silicosis cases, OSHA has increased its enforcement efforts and reinforced existing safety measures. However, these regulations—while a step in the right direction—do not eliminate the risks of silica exposure, as nano-sized artificial stone silica particles are still inhaled, even when using wet-cutting and respirators.

This blog outlines OSHA’s latest silica regulations, their limitations, and why there is no truly safe way to fabricate artificial stone.

What Are OSHA’s Current Silica Exposure Limits?

OSHA’s Permissible Exposure Limit (PEL) for respirable crystalline silica remains:

• 50 micrograms per cubic meter of air over an 8-hour shift
• 25 micrograms per cubic meter as the Action Level, triggering mandatory exposure monitoring and safety measures

These limits aim to reduce exposure to natural stone and other silica sources, but the PEL was never intended to be a safe level, and it was developed for the much less hazardous natural stone.  Additionally, studies continue to show that it is virtually impossible to fabricate artificial stone at silica levels below the PEL.

OSHA’s 2025 Regulations and Their Limitations

OSHA has strengthened its monitoring and enforcement efforts in 2025. However, experts emphasize that no safety measures can fully prevent the inhalation of nano-sized silica particles released when fabricating artificial stone.

1. Increased Use of Wet-Cutting Techniques

OSHA strongly encourages wet-cutting methods to reduce silica dust in stone fabrication and masonry work. Wet-cutting helps minimize visible dust, but studies have shown that nano-sized silica particles are still far above the PEL.

• Source: Australian research found that wet cutting reduces but does not eliminate respirable silica dust. (Study on Silicosis in Artificial Stone Workers)

2. Respiratory Protection Requirements

OSHA requires respirators when silica levels exceed the PEL.   
Cal-OSHA requires respirators whether or not testing shows levels are above the PEL.  However, artificial stone silica goes right through an N95 mask, and even dual cartridge filtered respirators.     Only Powered Air Supplied Helmets can block artificial stone silica, however they must be used in conjunction with wet equipment to reduce dust, but the helmet becomes splattered with water and the worker cannot see.

• Source: Studies on respirable crystalline silica show that ultra-fine silica particles can bypass respiratory filters, leading to continued inhalation.

3. Medical Monitoring for Exposed Workers

Workers exposed to silica at or above the Action Level (25 µg/m³) for 30+ days per year must be offered medical screenings, including chest X-rays and lung function tests. However a chest X-ray misses silicosis most of the time..

• Source: OSHA’s Medical Surveillance Guidelines

4. Exposure Control Plans and Air Monitoring

Employers must implement written exposure control plans and conduct regular air monitoring in workplaces with silica exposure risks. However, because artificial stone contains extremely high silica concentrations, even workplaces that follow all safety protocols cannot fully eliminate airborne silica dust.

• Source: OSHA’s Silica Standards

Why Artificial Stone Fabrication Remains Dangerous

While OSHA’s regulations aim to reduce silica exposure, they do not eliminate the risks, particularly for artificial stone workers. Nano-sized silica particles remain airborne despite wet-cutting, ventilation, and respiratory protection. This is why all health organizations and government researchers believe that artificial stone itself is the problem.

The only way to truly protect workers is to stop manufacturing and using engineered stone altogether—as seen in Australia, where it was banned in 2024..

Conclusion

OSHA’s new silica regulations in 2025 reinforce safety standards and enforcement, but they do not eliminate the risks of artificial stone fabrication. Nano-sized silica dust remains a major hazard, even in workplaces that strictly follow OSHA’s guidelines.

For workers exposed to artificial stone silica dust, the risk of developing silicosis and other lung diseases remains high. If you or a loved one has been diagnosed with artificial stone silicosis, or you think you may have it, you may have legal options. Brayton Purcell LLP has decades of experience advocating for workers affected by occupational diseases. Contact us today to learn more about your rights and potential compensation.