Technological Advances and Material Innovations in the Stone Industry Post-Silica Ban

Following Australia's ban on engineered stone, the stone industry has made technological innovations to reduce health risks from high-silica materials. Companies now use safer alternatives and new technologies to minimize exposure to harmful silica dust, offering fresh opportunities for stone industry jobs in Australia. The industry is also moving towards natural stone and low-silica composite materials.

1. Sintered Stone

Neolith and similar companies make sintered stone products that look like natural stone but have much less silica (1-9%).?

Created with natural materials under high pressure and heat, sintered stone is a rugged, low-silica option for countertops and floors.

• Durability: Sintered stone is highly durable and resistant to scratches, stains, heat, and UV rays. It surpasses the durability of natural and engineered stone, making it ideal for outdoor use.
• Price: Due to complex manufacturing processes, sintered stone is pricier than granite and marble, but it offers long-term value with its durability and low upkeep. Engineered stone, like quartz, is usually cheaper than sintered stone, but prices vary by brand and quality.
• Availability: Sintered stone is less readily available than granite, marble, and quartz due to its newer presence in the market, with options limited to certain manufacturers like Neolith.

2. Silica-Free Engineered Stone

Manufacturers like Neolith are working on silica-free engineered stone, aiming to introduce new colour options by 2024 for safer products with the same aesthetic and functional qualities.

1st. Raw Material Selection

Manufacturers use silica-free materials like feldspar, recycled glass, and ceramics, held together by organic or inorganic binders, to create products free of crystalline silica.

2nd. Mixing and Blending

Raw materials and binders are measured and mixed to create a uniform blend that achieves the desired properties and aesthetics.

3rd. Molding and Shaping

The mixture is poured into moulds for countertops, tiles, and custom designs. High-pressure compaction ensures a robust and durable structure.

4th. Curing and Hardening

To harden the material, the moulded slabs are cured using heat, UV light, or chemicals. Vibration and compression help strengthen the material.

5th. Surface Finishing

After curing, slabs are cooled and undergo surface finishing processes like grinding, polishing, and sealing to achieve the desired quality and appearance. Depending on preferences, different techniques can create either a smooth, glossy surface or a matte finish.

6th. Quality Control and Testing

Final slabs undergo thorough quality checks to confirm they meet industry strength, durability, and aesthetic consistency standards. Physical properties like hardness, scratch, and stain resistance are tested for performance.

3. Technological Innovations in Advanced Dust Control Technologies

Image Source: stonespecialist.com

In light of the increased understanding of the hazards associated with silica dust, the industry is moving towards implementing more robust dust control strategies.?

These measures encompass upgraded ventilation systems, utilization of wet-cutting methods, and the deployment of enhanced personal protective equipment (PPE) to mitigate the risk of workers being exposed to potentially harmful dust particles during cutting and processing activities.

4. Resin-Based Alternatives

Research into new resin-based alternatives aims to replace traditional engineered stone by reducing or eliminating silica content, ensuring durability and safety. These alternatives differ mainly in silica content and composition: resin-based options use synthetic resins and fillers, sintered stone contains natural silica in a less harmful form, and silica-free engineered stone uses recycled materials and polymers.?

While all three are engineered for durability, resin-based and silica-free options aim to be safer by removing silica. In contrast, though safer than traditional stone, sintered stone still contains some silica.

Education and Training

In response to the engineered stone ban, there is a strong focus on educating workers about safe handling practices, which is vital for supporting the growth of trade jobs in Australia. Safe Work Australia is creating guidelines and support materials to help the industry comply with the latest safety standards.?

The implemented training includes educating workers on the properties, risks, and safe handling of alternative materials, operating enhanced ventilation systems, using wet-cutting techniques to minimize dust, maintaining PPE, and preparing for emergencies related to new materials. Additionally, businesses and workers are trained on regulatory compliance and reporting procedures to ensure adherence to the ban on engineered stone.

Explore our detailed guides and resources to stay informed about the latest developments and ensure compliance with new safety standards. For a more comprehensive look at the Technological Advances and Material Innovations in the Stone Industry Post-Silica Ban, visit the full guide on our website.