Dust in the Details: Managing Silicosis Risk in Shipyard Operations

This post originally was published by Marine Log and is reprinted here with permission.

Silicosis may be centuries old, but for today’s shipyards, it’s a modern-day liability hiding in plain sight. From abrasive blasting and surface prep to cutting and coating removal, ship repair operations regularly generate airborne crystalline silica. Without proper controls, this dust can cause irreversible lung disease, posing long-term health risks for workers and long-tail liability risks for shipyard owners.

As OSHA renews its focus on crystalline silica exposure and insurers reevaluate how they underwrite shipyard risks, maritime industry leaders must treat silicosis not just as a compliance concern but as a strategic risk management issue. Doing so protects both the workforce and the bottom line.

The Silent Threat in Shipyard Dust

Silicosis is a serious, irreversible lung disease caused by inhaling microscopic silica particles commonly released during abrasive blasting, grinding, and cutting.

Shipyards face elevated risk due to:

• Confined spaces with poor ventilation
• High-exposure tasks like blasting and weld prep
• Frequent subcontractor turnover complicating exposure control

Even indirect exposure in shared spaces can be harmful. With symptoms often surfacing years later, proactive dust control and medical surveillance are critical to protecting workers and managing long-term liability.

Compliance Is the Baseline, Not the Goal

OSHA’s maritime standard for respirable crystalline silica includes specific requirements for:

• Conducting exposure monitoring
• Implementing engineering and work practice controls
• Providing appropriate respiratory protection
• Administering medical surveillance programs
• Maintaining recordkeeping and delivering worker training

But compliance alone won’t protect shipyards from long-tail liability. Under the United States Longshore and Harbor Workers’ Compensation Act (USL&H) workers’ compensation rules, the last maritime employer is often held responsible for occupational disease claims, even if the bulk of the worker’s exposure occurred decades earlier for a different company.

Plaintiff attorneys have seized on this legal structure, launching marketing campaigns to recruit former shipyard workers for silica-related lawsuits. Once claims surface, companies without strong documentation and controls may face six- or seven-figure exposures, even without fault.

Proactive Risk Management Strategies

To stay ahead of regulatory and legal risk, shipyards must take a comprehensive approach to silica mitigation, including the following:

1. Medical Monitoring and Documentation

• Conduct pre-employment and exit chest X-rays to establish a medical baseline and track lung changes over time.
• Perform periodic pulmonary function testing.
• Maintain thorough exposure and medical records.
• Train employees on symptoms, safety practices, and medical rights.

2. Engineering Controls

• Use vacuum-assisted blasting and wet methods to reduce dust.
• Install local exhaust ventilation in enclosed or confined spaces.
• Enclose dusty operations to prevent migration across worksites.

3. Administrative Controls

• Rotate employees to limit exposure duration.
• Post clear signage and restrict access to hazard zones.
• Maintain a written silica exposure control plan.
• Vet subcontractors to ensure alignment with your silica protocols.

Medical surveillance protocols are a critical component of risk management in shipyard operations. These controls not only safeguard worker health but also enhance a shipyard’s ability to defend against future claims.

Through policy reviews and loss history analysis, it’s clear that missing exposure records or the absence of baseline imaging can significantly weaken a claim’s defense. That’s why integrating medical surveillance, such as pre-employment and exit evaluations, into standard onboarding and separation procedures is strongly recommended. This approach protects employees and strengthens an organization’s position with underwriters when negotiating terms, deductibles, and exclusions.

Insurance Considerations and Long-Tail Liability

Silicosis introduces complex insurance challenges, triggering pollution exclusions, blurring lines between occurrence and claims-made coverage, and increasing defense costs under USL&H.

Insurers are placing greater emphasis on silica controls, subcontractor oversight, and medical surveillance. Shipyards with strong documentation—like baseline X-rays and exposure logs—are better equipped to defend claims and secure favorable terms. Proactive risk management can lead to broader coverage and better pricing, while gaps in safety protocols may result in higher premiums and restrictive endorsements.

Building a Culture of Prevention

A safety plan is only as strong as the culture behind it. Leadership must model safe behaviors and empower employees to speak up. Reinforcing that silica dust is a serious health hazard—not just a nuisance—is key.

Toolbox talks, mentoring, and visual training help embed daily habits that keep silica risks top of mind and create a shared sense of responsibility across the workforce.

Don’t Let Dust Derail Your Shipyard

Silicosis is preventable—but only with proactive action. With increased OSHA oversight and rising legal scrutiny, shipyards must prioritize silica mitigation to protect workers and avoid costly claims, fines, and insurance fallout.

Silica dust may be invisible, but the consequences are clear. Managing this risk with foresight and diligence isn’t just best practice; it’s essential to a resilient and responsible shipyard.

Related Reading: Your Crew, Your Risk: A Practical Guide to Jones Act Compliance and Coverage

The above information does not constitute advice. Always contact your insurance broker or trusted advisor for insurance-related questions.