The surface industry, particularly engineered stone, is facing a new set of challenges as the dangers of silica dust exposure come to light. In Australia, stringent regulations have been introduced aimed at protecting workers. These changes are expected to have both short- and long-term effects on the industry, with manufacturers and designers forced to adapt to evolving safety standards and growing demand for sustainable alternatives.
Australia’s ban on the use, supply, and manufacture of engineered stone came into effect in July 2024 to address workplace safety, specifically the risk of silicosis caused by exposure to crystalline silica dust, after years of campaigning from doctors, trade unions and trade workers given the high numbers of industry workers diagnosed with silica dust-related conditions, after being exposed during the cutting and processing of the material.
The ban, however, comes with dual consequences: manufacturers are now under pressure to develop surfaces with low or zero silica content, while users are turning toward alternatives like natural stone, porcelain, and engineered stone products that meet strict safety standards.
At Milan Design Week 2024, it was clear that the rest of the world was taking note, with launches and showcases such as Lapitec’s 100% Natural and silica-free surface exhibition and Cosentino’s low-silica Silestone range among others. So, will other countries including the UAE follow Australia’s lead on the ban, and how fast can the industry adapt?
According to Eddy Abou Khalil, Regional Director for Cosentino in the Middle East and India, while regulations enforcing workplace safety are essential, it’s unlikely other regions will enforce such a ban.
“The Australian ban is a unique scenario,” says Abou Khalil. “We don’t expect other regions to follow suit. In fact, most other countries feel that better health and safety regulations is more efficient than a ban of one type of product.” Abou Khalil highlights the danger of focusing solely on engineered stone, as other materials also contain high levels of crystalline silica. A more holistic approach to regulation could avoid creating a false sense of safety, though the ban may still have a positive ripple effect on the industry.
“It cannot be denied that there has been a rampant lack of safety compliance in certain markets,” Abu Khalil says. “This ban will enforce tighter control and regulation. Silicosis is a preventable disease and actions must be taken to create a safer workspace for tradespeople.”
Manufacturers are increasingly focusing on safer alternatives with Australia leading the charge in regulating silica content. Cosentino has been at the forefront of innovation, offering products like Dekton and Sensa as alternatives to traditional engineered stone. Furthermore, the company has invested significant resources into reducing silica content in its Silestone range.
“By 2022, we successfully achieved below 50% silica across the entire range of Silestone colours,” Abou Khalil says. “Last year, all production was below 40%, with 85% of the product between 40% and 11%, and 15% between 10% and 2% crystalline silica content.”
While the immediate impact of the Australian ban may be contained, the long-term effects on consumer choices and market trends could be profound. With an increasing focus on safety and sustainability, there may be a rise in demand for alternative materials such as porcelain, natural stone, and low-silica engineered surfaces.
“The shift toward porcelain is definitely something we’re seeing more of, and there are a few key reasons why people might be leaning that way,” says Vishwa Kundariya, co-founder of ClayArk, a Dubai-based company that specialises in manufacturing porcelain tiles and slabs.
“In terms of the current trends, the popularity of porcelain is increasing due to innovations in manufacturing and design. It’s being used more frequently in contemporary and modern interiors,” she says.
Beyond safety, sustainability has become another major focus for manufacturers, clients and end-users alike. “Made from natural materials like clay, porcelain tends to have a lower environmental impact than some engineered stones.,” says Kundariya.
As the industry continues to shift toward eco-friendly materials, manufacturers are exploring ways to achieve cradle-to-grave sustainability for those engineered products, too.
“Expect more innovation in terms of material and production process. Manufacturers will push to achieve hyper-realistic design, ultra-large formats, and ultra-low crystalline silica content,” says Abou Khalil, hinting at a future where aesthetics, performance, and safety converge.
He remains optimistic about the future, predicting continued innovation and emphasising regulatory compliance. “Manufacturers and designers who stay ahead of these changes and focus on sustainable products will be well-positioned to meet the demands of an increasingly eco-conscious market.”