My name is Danny Morning from Letterkenny and my background was in quality assurance.
Approximately four years ago I was watching a young man cutting a wall for chasing purposes and I thought it must be one of the worst jobs there is.
After some research I learned that cutting into concrete blocks is the most dangerous job in construction with the inbuilt risk of Respirable Crystalline Silica Dust (RCS) exposure.
The friction when cutting concrete blocks creates Respirable Crystalline Silica Dust (RCS).
RCS is known in many circles as the New Asbestos as is following the very same path as asbestos has done in the past.
Construction workers make up 75% of all workers exposed to Respirable Crystalline Silica Dust.
Exposure to RCS can cause Silicosis, Lung Cancer, COPD and generally takes 10 years + to manifest.
The HSE have calculated that for every single death resulting from a construction accident,
100 construction workers die from Respirable Crystalline Silica Dust exposure.
I when about finding a solution that would not cost the contractor more money and would fit into the current process:
This included the – Block manufacturing process – DOP Testing requirements (strength etc.) – Block laying process – Plastering process.
It sounds simple, but we ended up with a block that has lines already in them when produced.
We call “Chased Blocks” – No Cutting Needed.
The lines do not affect the strength of the block (please see test results on website) and all inner walls could be built with these blocks, leaving chases throughout the complete structure.
Even load bearing walls can be built with two blocks tied back to back, leaving the lines available on both sides.
The block layers DO NOT need to waste time aligning these blocks.
Chased Blocks will serve the same function even when the lines are staggered.
Over the past two decades there have been many studies commissioned and directives raised by the European Commission on RCS.
All concluding that the best solution to this health issue is to DESIGN OUT and use PRE-CUT MATERIALS where possible.
(please check some of the E.C. Directives etc. listed on our website.)
In January 2022 The Irish HSA have revised their Chemical Agents & Carcinogens Code of Practice.
“Work involving exposure to respirable crystalline silica generated by a work process is now listed
as a carcinogenic process in Schedule 4 of this Code”.
(Please see HSE official information sheet on our website)
This means an Employer must now do what is “Technically Possible” to eliminate or minimise RCS exposure.
If pre-cut materials are available, then they must use them.
In Ireland, approximately 90%+ of blocks used are the standard 100mm (4 inch) blocks.
Chased blocks are the identical outer size and would be a seamless transition for contractors.
Although Chased blocks are slightly more expensive to produce (we estimate 15c per block).
This extra cost will be easily recouped by the contractor
*) The Contractor does not need to pay to have the walls cut for chasing purposes.
*) The job can run much faster with no risk of RCS exposure to other trades working in the area.
(Calculations show it takes 24 hours for dust to settle in an average room – 7 hours per meter)
*) The Contractor does not need to pay to have extra chases due to late design changes.
*) Cleaning up after wall cutting.
*) Dealing with Law Suits due to RCS exposure.
Now a construction worker does not need to get sick in order to have a huge claim against the firm (this includes subcontractors).
If he
*) Did not receive all information in relation to all the dangers of RCS exposure prior to commencing the task in writing.
*) If he learns that the contractor did not used pre-cut materials when they should have.
Then he has a clear cut case for huge money against the company.
Unless the insurance companies are willing to pay out on their behalf then the construction companies are in a very venerable position.
Where we are at now.
We did successfully have a property built using Chased Blocks with no issues.
We have had the Irish patent granted and a total of 23 European design registers also granted.
We have 23 U.K. design registers also granted.
We have the PCT (European) and U.K. patents pending.
(Details are on the website).
We are beginning to issue licenses to block manufactures which will permit them to produce and sell Chased Blocks.
We hope Chased Blocks will be available throughout the country within 4 – 6 months.
A few important points to reiterate
*) All inner walls of a property is built using Chased Blocks, so chased are available everywhere.
*) Block layer does NOT need to waste time aligning up the lines on these blocks.
*) It is now the law for contractors to use available alternative processes to reduce RCS exposure to construction workers.
Thank You for your time.
Kind Regards: Danny Morning.
T: 0749129366
M: 0868179773