Moreno-Martín, VeronicaLópez, MariaBou, DavidFraga, SóniaTeixeira, João PauloLópez-Lilao, AnaSanfélix, VicentaMonfort, EliseoViana, Mar2026-02-032026-02-032025-01-25Int J Hyg Environ Health. 2025 Mar:264:114523. doi: 10.1016/j.ijheh.2025.114523. Epub 2025 Jan 251438-4639http://hdl.handle.net/10400.18/10797Research on nanoparticle (NP) release and potential exposure can be assessed through experimental field campaigns, laboratory simulations, and prediction models. However, risk assessment models are typically designed for manufactured NP (MNP) and have not been adapted for incidental NP (INP) properties. A notable research gap is identifying NP sources and their chemical, physical, and toxicological properties, especially in real-world settings. This work aims to provide insights into the release and physico-chemical properties of INP while contributing to improving models for INP release. INP release was evaluated through a case study in a ceramic tile firing facility, where aerosol (10 nm - 10 μm) properties were determined. The Control Banding (CB) Nanotool model was applied to test outputs based on provided input parameters. Results: demonstrate the constant generation and release of INP during tile firing, with NP concentrations up to 68711/cm³ and mean diameters of 37 nm, with 95% smaller than 100 nm. Particle morphology was mostly spherical, suggesting nucleation from precursor gases as the main formation mechanism. INP chemical composition was driven by primary ceramic components, while trace elements like Ni and Ti exhibited sizedependent patterns. In vitro cell viability tests indicated low to medium cytotoxicity of PM2 aerosols, decreasing human alveolar epithelial cell viability in a concentration-dependent manner. Applying the risk model with varying input parameters revealed that the risk level (RL) based on severity scores decreased when aerosol size distribution data were used, illustrating the model’s sensitivity to input variables. We conclude on the need for comprehensive experimental datasets to support risk assessment models and achieve effective risk management strategies in real-world scenarios.Highlights: -Experimental datasets are essential as current models cannot reproduce INP exposure risks. -Incidental NPs were monitored and characterised (phys-chem properties and cytotoxicity). -A size-dependent contribution of tracer metals was observed (0.0156–0.095 μm). -Exposure to PM2 was linked to low-medium cytotoxicity in human alveolar epithelial cells. -Risk severity score decreased when aerosol size distribution was added in CB Nanotool.engIncidental NanoparticlesHuman ExposureIn Vitro TestingIncidental NanoparticlesRMMRisk Management ModelsUltrafine ParticlesGenotoxicidade Ambientaljournal article10.1016/j.ijheh.2025.1145231618-131X39862643