Engineering Control for Respirable Crystalline Silica at Open-Air Asphalt Milling Operator Stations: Efficacy of an External Water Spray Barrier

Open-air asphalt milling generates hazardous respirable crystalline silica (RCS), posing severe risks to operators of legacy machines lacking enclosed cabs. This study evaluates a novel, standalone retrofit water spray system designed to intercept fugitive dust. Field validation across 11 road maintenance sites involved particle characterization and paired system-off/on exposure monitoring. Results indicated a Mass Median Aerodynamic Diameter (MMAD) of 6.12 µm, confirming the efficacy of fine-atomizing nozzles (0.3 mm) for capturing respirable fractions. The system achieved RCS suppression efficiencies ranging from 60% to over 85% under low-to-moderate wind conditions (<2.5 m/s). A comparative analysis revealed no significant performance gain from larger 0.5 mm nozzles, supporting the use of smaller orifices for optimal water conservation. However, suppression efficacy degraded significantly when crosswinds exceeded 2.5 m/s, indicating a potential operational boundary. This retrofit solution provides a scientifically validated, cost-effective engineering control for reducing occupational silica exposure in aging road maintenance fleets.