Study Finds Tunnel Workers Face Increased Silicosis Risk

One in 10 Australian tunnel workers will likely develop silicosis in their lifetime, according to findings that come as artificial stone workers are already pursuing lawsuits over development of the fatal lung disease in the U.S.

Growing concerns over silicosis, a potentially fatal lung disease caused by inhaling silica dust, have increased worldwide due to the routine exposure faced by artificial stone cutters and quartz countertop workers.

In a new study published in Annals of Work Exposures and Health on April 8, Australian researchers warn that silicosis risks are not limited to those cutting and installing kitchen and bathroom countertops, but also can endanger those working on underground construction projects as well.

Silicosis is an irreversible lung condition known only to be caused by routine exposure and inhalation of silica dust. It begins with lung inflammation and scarring, and eventually can develop into lung failure, and the need for transplant surgery.

The artificial stone cutting and fabricating countertop industry is considered a primary source for silica dust exposure. Also known as “engineered stone,” quartz countertops are believed to be a significant silicosis risk for stone cutters, who regularly inhale large amounts of silica dust as they make countertops for consumers’ kitchens and bedrooms.

In this new study, researchers from the University of Sydney, in Australia, predict that about 10% of workers involved in three different tunneling projects in Queensland may develop silicosis due to worksite conditions.

While the tunnels help with transportation, energy and environmental preservation, researchers say they have found an increase in work-related illnesses among tunnel workers, much of which may be attributable to inhalation of respirable crystalline silica (RCS), also known as silica dust.

The researchers looked through documents on hundreds of air monitoring tests conducted in three Queensland tunnel projects between 2007 and 2013, and examined how many workers were exposed. They then used modeling to estimate the number that would eventually develop silicosis.

The analysis predicts that out of a group of approximately 2,000 tunnel workers, 200 to 300 would develop silicosis over the course of their lifetimes. About 20 would develop lung cancer, the researchers estimated.

“Our projected rate of silicosis, 10%, is the same as the rate of silicosis recorded by a government inquiry in 1924 which investigated silicosis among workers who built Sydney’s sewers,” the researchers said in a press release announcing the study’s results. “So it doesn’t seem things are any better in terms of silicosis risk in underground work than a century ago.”

They noted that the use of respiratory protective equipment (RPE) was not mandatory, and many workers did not use them. In some cases, reusable respirator facepieces were dirty and lacked signs of maintenance, with an estimated 5% to 10% of workers not using them as recommended.

The researchers called for more studies and for improved silica dust exposure control at tunnel construction sites.

April 2025 Silicosis Lawsuits Update

With more attention turned on silica dust exposure risks, a growing number of silicosis lawsuits have been filed over the past few years, almost exclusively focused on the artificial stone countertop industry.

Each of the claims present similar allegations, that employers and manufacturers of quartz countertops failed to provide adequate warnings and protection to workers who were exposed to silica dust. This alleged negligence has led to severe and sometimes fatal respiratory conditions, including chronic silicosis.

The stone cutter silicosis lawsuits often involve individuals who have worked for years in industries such as sandblasting, mining, construction, and manufacturing products like quartz countertops, concrete and glass, where workers are frequently in contact with silica. 

Plaintiffs argue that despite longstanding knowledge of the risks associated with inhaling silica particles, sufficient measures were not taken to educate or protect workers, violating occupational safety regulations.

As a result, lawyers across the United States are providing free case evaluations for individuals who were exposed to silica dust throughout their careers and have subsequently been diagnosed with silicosis.