Matt Morgan, a commercial leader in Tetra Tech’s occupational health team, shares why proactive silica surveillance is essential for protecting workforce health and ensuring compliance.
Respirable crystalline silica (RCS) remains one of the most significant, and preventable occupational health risks in industries ranging from construction and quarrying to manufacturing. Repeated inhalation of fine silica dust can lead to irreversible lung conditions including silicosis, chronic obstructive pulmonary disease (COPD) and increased risk of lung cancer. Protecting employees from these risks it both an essential compliance requirement and a practical step forward towards maintaining and health and productive workforce.
The importance of early detection
Health surveillance for silica exposure is more than a compliance activity; it is a proven method of identifying early lung changes long before symptoms appear. Regular chest X-rays and respiratory function tests allow organisations to detect abnormalities as early as possible, supporting timely clinical intervention and preventing disease progression.
Beyond individual health outcomes, early detection also plays a vital role in organisational resilience. Reducing long-term sickness absence, maintaining operational continuity, and demonstrating a proactive commitment to employee wellbeing all contribute to a stronger, more sustainable workforce.
HSE guidance
The Health and Safety Executive (HSE) sets clear expectations for controlling exposure to respirable crystalline silica, including robust health surveillance for workers regularly exposed at or above action levels. The workplace exposure limit for RCS is 0.1 mg/m³ (8 hour TWA), with increased surveillance recommended when exposure reaches 0.025 mg/m³—a threshold used in some HSE guidance to prompt additional controls.
Embedding compliant, evidence-based surveillance programmes not only reduces risk; it also provides organisations with auditable assurance that they are meeting Control of Substances Hazardous to Health (COSHH) requirements and demonstrating responsible risk management.
A persistent and preventable UK health burden
Despite improved awareness, silica-related conditions remain a significant contributor to occupational lung disease in the UK. Hundreds of workers continue to be diagnosed with silicosis and associated conditions every year, with silica exposure contributing to a notable number of work-related deaths.
How we can help
Tetra Tech combines clinical expertise with practical delivery models to make silica health surveillance efficient, reliable, and accessible for organisations of all sizes.
Mobile Onsite Digital Chest X-Ray Units: We bring accredited radiology services directly to your premises, reducing operational disruption and improving participation rates, critical factors in maintaining successful long-term surveillance programmes.
Comprehensive Respiratory Function Testing: Our clinicians conduct spirometry and pulmonary function testing either onsite or at our clinical centres, enabling early identification of respiratory impairment.
Clear, Actionable Clinical Reporting: Employees receive confidential, clinician-led reports with clear explanations and recommended next steps, while employers receive anonymised or individualised summaries to support effective risk management and compliance.
Long-Term Surveillance Programmes: We develop tailored testing schedules aligned with HSE expectations, exposure levels, and workforce characteristics, ensuring ongoing protection and compliance.
Silica surveillance should cover anyone with meaningful exposure to respirable crystalline silica, including those working in stone fabrication, quarrying, mining, construction, demolition, foundries, and manufacturing environments.
HSE guidance typically recommends baseline assessments when employees begin higher-risk roles, followed by repeat testing every one to three years depending on exposure intensity and clinical indicators.
Frequently Asked Questions
Can silica dust be removed from the lungs?
No reliable method exists to remove silica particles already embedded in lung tissue. Prevention of further exposure, early detection, and clinical management are the only practical approaches to limit disease progression. When disease or significant risk is identified, Tetra Tech clinicians will advise on removal from exposure, clinical care pathways, workplace adjustments, and redeployment where appropriate. With employee consent, we can liaise directly with insurers and pension providers and provide the medical evidence required.
Is silica as dangerous as asbestos?
Silica and asbestos are distinct in composition, but both can produce severe and irreversible lung disease when inhaled over prolonged periods. Similar to health impacts caused by asbestos, long‑term RCS exposure can cause silicosis and COPD, and increases lung cancer risk. Robust exposure control, appropriate personal protective equipment, and regular medical surveillance are therefore essential. Tetra Tech can assist with control strategy advice and ongoing monitoring.
How often should workers have silica X rays and lung tests?
HSE recommends a baseline assessment when a worker begins a high risk role, with repeat surveillance generally every one to three years depending on exposure intensity, measured levels and clinical risk. High risk environments or early indicators of disease may necessitate more frequent review. Tetra Tech will assess your exposure profile and propose an appropriate surveillance schedule that aligns with HSE/COSHH expectations.
About the author
Matt Morgan
Matt Morgan is a commercial leader with over 20 years’ experience in occupational health, safety and consultancy.
Since 2005 he has specialised in protecting the health and wellbeing of clients and employees by designing and delivering pragmatic, people‑centred, compliance‑led solutions across multiple sectors in the UK and internationally. Combining commercial acumen with hands‑on delivery, Matt leads business development, tendering, and seamless contract implementation with a focus on operational practicality, risk mitigation, and continuous improvement to drive client satisfaction and long‑term repeat business.