Talking about crystalline silica and Solid Surface has become an increasingly important conversation in the construction and interior design industries. Because Solid Surface and engineered stone exist in the same marketplace as hard, man-made worktop materials, many people confuse the two. In fact, they are entirely different products with completely different chemical compositions and fabrication profiles.
Health and material safety are of paramount concern for fabricators, specifiers, and end-users alike. Understanding the exact differences between the surface materials on offer is essential when specifying for your next residential or commercial project.
What Is Silicosis and Why Is Crystalline Silica a Concern?
Silicosis is an exceptionally serious, irreversible, and incurable lung condition principally caused by the long-term inhalation of respirable crystalline silica dust over an extended period[cite: 1]. The severity of the condition causes swelling in the lungs, leading to permanent scarring (fibrosis)[cite: 1]. In short, the lungs can no longer function properly, and in extreme cases stop working entirely—a debilitation comparable in severity to Asbestosis following decades of use in the construction industry[cite: 1].
While the solid, installed form of stone is not hazardous, the danger lies in the respirable dust released during unavoidable fabrication and installation processes—such as cutting, grinding, trimming, drilling, sanding, and polishing.
Following studies first conducted in Australia—which revealed that 12% of workers fabricating materials containing crystalline silica had developed silicosis—engineered stone was banned across Australia in 2024[cite: 1]. This decisive action has highlighted material safety globally, including here in the UK, where the first documented cases of engineered-stone silicosis have emerged and regulatory scrutiny has intensified.
How Much Crystalline Silica Is in Natural & Engineered Stone?
Crystalline silica (silicon dioxide) is a naturally occurring mineral and a common component in many natural and artificial stone products on the market[cite: 1]. Examining the typical composition of these materials demonstrates the extent to which silica dioxide is present[cite: 1]:
- Quartz (Engineered Stone): Around 90%[cite: 1]
- Sandstone: Between 20% and 95%[cite: 1]
- Granite: Between 40% and 50%[cite: 1]
- Marble: Between 5% and 30%[cite: 1]
- Porcelain: Between 15% and 18%[cite: 1]
In man-made, artificial stone derivatives—which replicate the look of natural stone at a lower material cost—the average silica dioxide content is 44.6%, with some varieties reaching up to 94% crystalline silica[cite: 1]. Even newer "low-silica" variations introduced to the market still present a minimum of 10% crystalline silica in their composition[cite: 1].
Whilst wet cutting in a factory, alongside appropriate extraction, filtration, and respiratory equipment, can reduce exposure, it cannot fully eliminate exposure across all stages of production and installation, nor the airborne particles that remain present during and after work[cite: 2].
Solid Surface vs. Engineered Stone: 100% Crystalline-Silica-Free
Solid Surface (Acrylic Stone) has zero crystalline silica present in its material or chemical composition[cite: 2].
Unlike engineered quartz (which binds roughly 90% crushed quartz with polymer resin), Solid Surface is manufactured by curing a homogeneous blend of approximately one-third high-performance resin with two-thirds natural minerals and colour pigments (and occasionally recycled, crunched-up Solid Surface particulates). There are, principally, four elements in the composition of Solid Surface[cite: 2]:
- Aluminium Trihydrate / Tri-hydroxide (ATH): A safe mineral derivative and by-product of aluminium mining[cite: 2]
- Methyl Methacrylate: Clear acrylic[cite: 2]
- Acrylic Resin[cite: 2]
- Polymer & Pigments[cite: 2]
In addition to holding all appropriate international class ratings for fire, Solid Surface materials are non-porous, stain-resistant, non-toxic, and non-hazardous[cite: 2]. All materials offered by BSF Solid Surfaces are regularly tested and certified by international bodies to maintain compliance with up-to-date safety standards[cite: 2].
Safe Fabrication and Installation Standards at BSF
Production by skilled specialist fabricators, such as BSF Solid Surfaces, ensures that bespoke items are manufactured in well-ventilated factory environments using dedicated extraction and respiratory equipment to safeguard our team[cite: 2].
When installing on-site, appropriate extraction equipment meeting Class-M requirements is always used[cite: 2]. While uncollected Solid Surface sanding dust can irritate the throat if inhaled directly, there are no long-term health warnings or detrimental effects to either the fabricators working with the material or the end-user[cite: 2]. After installation, the most that will happen is that any residual airborne dust particles may take up to two days to fully settle, requiring only a simple clean-down—with zero health issues associated with inhaling small particles during this period[cite: 2, 3].
Beyond Safety: The Practical Design Advantages of Solid Surface
Choosing a zero-silica worktop material does not mean compromising on aesthetics or performance. Solid Surface is completely different from crystalline-silica-based products, offering unique advantages across residential and commercial projects[cite: 3]:
- Stone-Matched Aesthetics: The range of colours, veining, and finishes on offer matches those found across natural and artificial stone ranges[cite: 3].
- Seamless & Hygienic: Sheets are bonded with colour-matched adhesives to create inconspicuous seams with no crevices to harbour bacteria, mould, or grime.
- 3D Thermoformable: Unlike stone—where curves must be cut and carved from heavy blocks—Solid Surface can be heated, wrapped, and moulded to create sweeping curves and monolithic, seamless appearances[cite: 3].
- Fully Repairable & Refinishable: Solid Surface can be easily sanded and refinished on-site if scratched or damaged, making the investment timeless and removing the need for costly replacements[cite: 3].
- Sustainable Longevity: Many Solid Surface ranges include certified recycled content, and because the material will last in great condition for as long as you want it to, it supports true long-term sustainability[cite: 3].
A Responsible Approach to Industry Safety
This is a sensitive topic across our industry, as we have many friends and colleagues who work with engineered stone and invest heavily in tooling and processes to mitigate silica risks responsibly. However, because our own fabrication and installation processes generate harmless sanding dust, it is vital that our clients, contractors, and specifiers have complete peace of mind: Solid Surface is 100% silica-free, safe, can appear identical to stone, and is built to last[cite: 2, 3].
If you have any questions about material safety, technical specifications, or upcoming commercial or residential projects, please contact the BSF Solid Surfaces team on 01277 263603 or email info@bsfsolidsurfaces.com[cite: 3].