In brief
In marble processing plants, the most serious accidents happen while handling blocks and slabs, and the most widespread health problems come from dust and noise. Periodic inspection of lifting equipment and the rule of never standing under the load for block lifting, guards and interlocks on gang saws and bridge saws, and slip-resistant floors and residual current protection for wet cutting are the basic measures. Because the silica content of marble dust varies with the type of stone, measurement by an authorised laboratory, not estimation, is the basis.
Marble processing in Bilecik: from quarry to factory
The Bilecik Governorship notes that, alongside agriculture and livestock, mining, marble, ceramics and forestry account for a significant share of the province's economy. Blocks from the marble quarries are turned into slabs and cut-to-size products in processing plants around the provincial centre; marble plant safety is therefore one of the prominent topics in the province's industry. On the Bursa side, too, the fact that the Mustafakemalpaşa–Mermerciler OIZ (organised industrial zone) is dedicated to marble processing shows the sector's place in the region.
The quarry and the factory are two separate worlds of risk. Quarries are subject to special provisions of mining legislation and have their own issues such as slopes, blasting and plant traffic. This article focuses on processing plants, that is, the process from the moment a block enters the plant until the slab leaves for dispatch: block lifting, cutting machines, wet floors and dust.
Marble block handling and lifting
A marble block weighs several tonnes and is irregular in shape. These two features make marble block handling the highest-severity risk in the plant. Accidents usually happen in four ways: the block tips over, a sling or chain breaks, the load swings, or a worker is trapped between the block and a machine or another block.
Put measures in place in this order:
- Organise the block yard. The ground must be level and load-bearing, blocks must be chocked to stop them tipping, and stacking heights and passage widths between blocks must be set in writing.
- Have the equipment inspected. Overhead and gantry cranes, chains, slings and hooks, and construction machinery carrying blocks undergo periodic inspection at least once a year; for cranes, a load test is also carried out once a year. The inspection is carried out by an authorised person registered on EKIPNET (the Ministry's online register of periodic inspectors); you can track report dates with the OHS calendar tool. For the periods, see our article on periodic inspection periods.
- Look before every use. Slings and chains are checked for cuts, crushing and stretching, and hook safety catches are checked; damaged gear is set aside and tagged. For details, read our article on slings, chains and lifting accessories.
- Nobody goes under the load. The danger zone is marked during lifting; the person attaching the load moves to a safe distance before it is lifted. If the operator cannot see the load, a signaller is appointed.
- Plan feeding the gang saw. Positioning and securing the block on the gang saw trolley is covered by an instruction so that the lifting gear is not detached until the block is fully seated.
For rules specific to crane use, see our article on overhead crane safety.
Marble cutting machines: gang saws, bridge saws and sizing
The main types of marble cutting machine in a plant and their typical risks are:
| Machine | Function | Main risks | Key measure |
|---|---|---|---|
| Gang saw | Splits the block into slabs with multiple blades | Being trapped by the moving frame, injury during blade changes, noise | Perimeter guarding and interlocked access, energy isolation and lockout for blade changes |
| Bridge saw | Cuts slabs or blocks with a disc | Contact with the disc, ejected fragments, crushing as the bridge moves | Disc guard, safety distance around the bench, emergency stop |
| Sizing and edge-cutting lines | Cut slabs to size | Contact with the disc during manual feeding, cuts | Feeding aid, guard, cut-resistant gloves only on stationary parts |
| Calibrating and polishing line | Levels and polishes the surface | Contact with rotating heads, wet floors | Head guards, emergency stops along the line |
The common rule for all these machines is that maintenance, disc or blade changes and clearing jams are done with the machine stopped, its energy isolated and locked out. For the steps, see our article on lockout and tagout; for guard types, see machine guards.
Wet cutting: reduces dust, but strains floors and electrics
Wet cutting is the most effective way to suppress dust at source in marble processing and should clearly be preferred to dry cutting. However, water brings two new risks with it:
- Slipping: cutting water and marble slurry make floors slippery. Floors sloped to direct water to drains, channels kept clear, grated platforms around machines and boots with slip-resistant soles are needed. For general measures, see our article on preventing slips, trips and falls.
- Electricity: motors, hand tools and cables trailing on the floor in wet conditions increase the risk of electric shock. Panels and sockets suitable for wet environments, residual current devices fitted and regularly tested, and cables raised off the floor are essential. Details are in our article on earthing and residual current devices.
- Slurry ponds and treatment: ponds where cutting water collects are protected by guardrails and not left uncovered; on equipment such as filter presses, the energy is isolated before maintenance.
Marble dust and crystalline silica
Marble consists largely of calcite and dolomite; its quartz content is generally lower than that of granite and quartz-based engineered stone. This does not mean that marble dust is harmless. Some types of marble and veins may contain quartz; if granite or engineered stone is processed on the same line, the risk changes completely. Dry edge grinding, dry cutting with hand tools and cleaning with compressed air also produce far more dust than wet lines.
Base dust-related decisions on measurement, not estimation:
- Measurement. The Regulation on Dust Control requires dust measurements to be taken at intervals set in the risk assessment and when conditions change. Because the limit value for quartz is calculated according to the silica content of the dust, silica analysis should also be requested with the measurement. We plan measurements with authorised laboratories.
- Control at source. Convert dry operations to wet methods, use water-fed or extracted models of hand tools, and clean using wet methods or a vacuum with a suitable filter instead of sweeping and compressed air.
- Respiratory protection. For remaining exposure, respiratory protection of a suitable class is chosen; for selection, see our article on FFP1, FFP2 and FFP3 dust masks.
- Health surveillance. Workers exposed to dust have chest X-rays taken to the ILO standard; the workplace physician sets the frequency.
For the health effects of silica and interpreting measurement results, read our article on crystalline silica dust.
Slab storage, noise and other risks
Slab storage: cut slabs are usually stored upright on A-frame racks. On a rack that is loaded unevenly or unloaded from one side only, slabs can topple and crush a worker caught between them. Racks need to be fixed to the floor, both sides loaded evenly, and the slabs in front secured when a slab is being removed. Slab clamps and vacuum lifters are also included in the inspection programme as lifting accessories.
Noise: gang saws and cutting lines generate high noise. If exposure exceeds the upper exposure action value of 85 dB(A), wearing hearing protection and hearing tests are mandatory. For selection, see our article on choosing hearing protection.
Resin and filler: resins used for surface filling can cause skin allergies; gloves and ventilation are needed. For skin risks, read our article on occupational dermatitis.
Emergencies and first aid: serious accidents in marble plants are mostly crushing and trapping injuries and require correct response in the first minutes. If the plant is far from the provincial centre or a hospital, plan the number of first aiders not just by the legal ratio but by the shift pattern and the size of the site; depending on the hazard class, at least one first aider is needed for every 20, 15 or 10 workers. The route the ambulance will take to the block yard and cutting halls should be marked in the emergency plan and not blocked by stacked material.
Marble plant safety checklist
You can use the following list on a site walk:
| Area | Point to check |
|---|---|
| Block yard | Ground level, blocks chocked, passageways clear |
| Cranes and accessories | Periodic inspection report valid, slings and chains checked before use |
| Gang saw | Perimeter guarding and interlocked access working, lockout procedure for blade changes in place |
| Bridge saw | Disc guard in place, emergency stop tested |
| Floor | Water flows to drains, no slurry build-up, slip-resistant boots worn |
| Electrics | Residual current device fitted and tested, cables raised off the floor |
| Dust | Measurement with silica analysis up to date, no dry cleaning |
| Slab racks | Racks fixed, both sides evenly loaded |
| Noise | Hearing protection worn according to measurement results |
We visit plants in Bilecik from Bursa, on the same route as businesses towards İnegöl and Bozüyük. For our service model, see our Bilecik OSGB page; for recording risks, see our risk assessment and OHS specialist services; and for the other links in the building materials chain, see our construction sector page.
Frequently Asked Questions
Does marble dust cause silicosis?
Silicosis is caused by crystalline silica. The quartz content of marble is generally low, but it varies with the type of stone and its veins; if granite or engineered stone is processed at the same plant, exposure increases. That is why dust measurements should include silica analysis and chest X-rays should be taken to the ILO standard.
Is dust measurement needed if wet cutting is used?
Wet cutting significantly reduces dust, but it does not cover every operation. Dry edge grinding, hand tools and dry cleaning are separate dust sources. The need for measurement is determined by the risk assessment; measurements are repeated when conditions change.
How often are cranes lifting blocks inspected?
Cranes and other lifting equipment undergo periodic inspection at least once a year unless the standard or manufacturer specifies a shorter period, and a load test is carried out once a year. Slings, chains and hooks are also checked before every use.
Can marble slabs be carried by hand?
Small products can be carried by hand; however, because large slabs are heavy, brittle and have sharp edges, slab clamps, vacuum lifters or trolleys should be used. If manual handling is unavoidable, the load is carried as a team, with the slab held upright and wearing cut-resistant gloves.
What should be watched when changing a gang saw blade?
The machine is stopped, its energy isolated and locked out, and mechanical safety is provided to prevent the moving frame from moving under its own weight. The change is made according to a written instruction, by trained people, wearing gloves that provide cut protection.
A risk assessment that identifies and scores hazards on site, links each measure to an owner and a date, and has a clear renewal schedule.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.