HSE Ceramics Guidance Series – Controlling Respirable Crystalline Silica

Practical Guidance for Controlling Silica Exposure in the Ceramics Industry

The HSE Ceramics Guidance Series (CR Series) provides practical task-specific guidance for controlling worker exposure to respirable crystalline silica (RCS) within the ceramics manufacturing industry.

Produced as part of the HSE COSHH Essentials programme, the guidance focuses on common ceramic production activities where silica-containing materials may be handled, processed or disturbed, creating airborne respirable dust capable of causing serious long-term health effects.

The guidance covers:

Glaze and colour preparation
Ceramic casting operations
Dry fettling
Kiln loading and unloading
Glaze spraying
Local Exhaust Ventilation (LEV)
Process enclosure
Housekeeping
Respiratory protection
Exposure control verification

The series provides practical examples of how engineering controls, good occupational hygiene practice and management systems can be combined to reduce worker exposure.

This resource is relevant to:

Occupational Hygienists
LEV Designers/Commissioners/Testers etc
Ceramics Manufacturers
Production Managers
COSHH Assessors
Health & Safety Professionals

Source Document

View HSE Guide Series here:

View HSE Guide Series

Source: Health and Safety Executive (HSE)
Document Type: COSHH Essentials Industry Guidance
Status: Current (2019)
Last reviewed by LEVCentral: June 2026

LEVCentral Expert Commentary

The HSE Ceramics Guidance Series remains one of the best examples of practical occupational hygiene guidance available to manufacturing industries.

Ceramic production frequently involves materials containing crystalline silica, including clays, fillers, glazes and other mineral ingredients. During handling and processing, these materials can generate respirable dust capable of penetrating deep into the lungs.

The guidance recognises that exposure risks vary significantly depending upon the activity being undertaken. For example, glaze preparation presents different challenges to dry fettling or kiln operations. As a result, the guidance adopts a task-based approach to exposure control rather than relying on generic recommendations.

This aligns closely with modern occupational hygiene principles, where understanding the process is often more important than understanding the material alone.

For LEV professionals, the guidance highlights several recurring themes:

Capture contaminants close to source
Prevent dust generation where practicable
Enclose dusty activities where possible
Maintain effective airflow control
Verify control effectiveness
Support engineering controls with good housekeeping

The principles described throughout the series remain directly applicable to many industries beyond ceramics, including:

Construction
Stonemasonry
Refractories
Brick and Tile Manufacturing
Foundries
Quarrying
Advanced Materials Manufacturing

From a LEVCentral perspective, the guidance provides an excellent example of how engineering controls and occupational hygiene work together to reduce the risk of occupational lung disease.

Key Learning Points

Respirable Crystalline Silica Is a Significant Health Hazard

Silica-containing materials used throughout the ceramics industry can generate airborne respirable dust capable of causing serious respiratory disease.

Different Tasks Create Different Exposure Risks

Glaze preparation, fettling, casting and spraying operations all present unique exposure challenges requiring tailored control measures.

LEV Should Be Applied Close to Source

Effective contaminant capture is most readily achieved when extraction is positioned close to the point where dust is generated.

Good Housekeeping Supports Exposure Control

Removing settled dust using suitable cleaning methods helps prevent secondary exposure and re-suspension of contaminants.

Exposure Controls Must Be Maintained and Verified

The presence of an extraction system alone does not guarantee protection. Controls must be inspected, maintained and tested to ensure ongoing effectiveness.

HSE Guidance Sheets Included Within the Series

CR0 – Advice for Managers

Provides an overview of silica risks, management responsibilities and exposure-control strategies within ceramics manufacturing.

CR1 – Glaze and Colour Preparation

Covers the weighing, handling and mixing of powders used to produce ceramic glazes and colours.

CR2 – Casting

Provides guidance on controlling exposure during ceramic casting operations.

CR3 – Dry Fettling

Addresses dust generation during finishing and trimming activities on unfired ceramic products.

CR4 – Kiln Loading and Unloading

Focuses on reducing exposure during the movement of products into and out of kilns.

CR5 – Spraying Glazes and Colours

Provides practical guidance on controlling airborne contaminants generated during glaze spraying activities.

Together, these documents provide a comprehensive framework for managing silica exposure within ceramic manufacturing operations.

Further Resources

Recommended Learning

Thought Leadership

LEVCentral Observation

The HSE Ceramics Guidance Series demonstrates the value of task-specific occupational hygiene guidance.

Rather than focusing solely on regulatory compliance, the guidance explains how exposure occurs during real manufacturing activities and provides practical solutions for reducing risk.

Many of the engineering principles described remain directly relevant across a wide range of modern manufacturing sectors.

For LEV professionals and occupational hygienists, the series remains an excellent example of how exposure-control strategies should be built around the process rather than the equipment alone.