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DuPont’s Awareness of the Dangers of Artificial Stone Product, Corian: 2014 – 2018

In a disturbing revelation published in the New England Journal of Medicine in 2014, a case report outlined the tragic story of a 64-year-old man who, after working with Corian for 16 years through grinding, machining, drilling, and sanding, succumbed to pulmonary fibrosis. This alarming case highlighted the lethal risks associated with exposure to Corian dust, particularly aluminum trihydrate, a key component of the material. Despite advanced medical interventions and the cessation of exposure to the hazardous dust, the man's health deteriorated over seven years, culminating in his death due to respiratory failure. Autopsy results confirmed the presence of aluminum trihydrate within his fibrotic lungs, underscoring a probable link between his occupation and the fatal lung disease.

DuPont, the manufacturer of Corian, was given the opportunity to respond to this case report by the New England Journal of Medicine. In their defense, DuPont's representatives, including their Chief Medical Officer and Director of Health and Environmental Sciences, attempted to downplay the connection between Corian dust and pulmonary fibrosis. They suggested the association was merely circumstantial and implied that the patient might have been exposed to other hazardous materials. Moreover, they challenged the source of the aluminum found in the patient's lungs, insinuating it could have originated from other industrial exposures, despite the absence of such evidence in the patient's work history.

This response from DuPont reflects a disturbing trend in the handling of safety information related to their products. Their 2014 Material Safety Data Sheet (MSDS) for Zodiaq, another quartz surface product containing a significant amount of crystalline silica, begins with the assertion that the product in its entirety is not hazardous. Such a statement is dangerously misleading, as it may prevent further scrutiny by users regarding the potential risks associated with the product's processing. The MSDS acknowledges the generation of dust during fabrication but ambiguously mentions that this dust "can contain" crystalline silica particles, failing to emphasize the inevitability of such exposure given the product's composition.

Furthermore, the MSDS inadequately addresses the severity of health risks posed by inhaling crystalline silica dust, suggesting that only "overexposure" could lead to silicosis. This insinuation dangerously underestimates the risks, as silicosis can develop even at exposure levels below the permissible limit. The provided safety instructions are vague and lack specificity, offering little practical guidance to workers on how to effectively mitigate these risks.

In a similar vein, DuPont's 2018 Safety Data Sheet for Corian (previously known as Zodiaq) identifies quartz and cristobalite as major components but then perplexingly states that "the product as such is not hazardous." This contradictory messaging continues with a series of "hazard prevention measures" that are either impractical or insufficiently detailed to offer meaningful protection against the known risks of crystalline silica exposure.

The handling and storage instructions provided in the safety data sheets further exemplify the inadequacy of DuPont's safety protocols. Generic recommendations such as "avoid dust formation" and "provide appropriate exhaust ventilation" fail to offer concrete solutions or standards that could effectively prevent the inhalation of hazardous dust.

This case and DuPont's subsequent responses shed light on a broader issue of corporate accountability and transparency in the face of occupational health risks. The evidence presented in the 2014 case report and subsequent studies, including a 2016 study by the National Institute for Occupational Safety and Health, underscores the need for a more rigorous examination of the chemical composition of dust generated from cutting Corian and similar materials. The high concentration of ultrafine particles, their potential pulmonary effects, and the presence of hazardous components like aluminum hydroxide demand a reevaluation of safety measures and exposure controls in workplaces where these materials are processed.

DuPont's handling of this situation, from their defensive response to the publication of misleading safety data sheets, raises critical concerns about the company's commitment to safeguarding worker health. It underscores the urgent need for stricter regulations and more transparent communication regarding the health risks associated with the fabrication and processing of synthetic materials like Corian.