BRISA tackles the urgent challenge of carcinogenic and emerging airborne industrial pollutants, linked to 53% of occupational cancers in the EU and 125,000 premature deaths annually. Energy-intensive industries remain key emitters of respirable crystalline silica, incidental nanoparticles, tVOCs, benzene, phenol, formaldehyde, bisphenol, BFRs, PFAS, PAHs, ultrafine particles, and microplastics, where current prevention strategies, monitoring methods, and regulatory frameworks are insufficient. The project applies a science-based, multi-layered methodology. Layer 1 consolidates regulatory, toxicological, and exposure intelligence into FAIR datasets and harmonised protocols. Layer 2 operationalises the Hierarchy of Controls by: (i) SSbD-based substitution routes (low-silica feedstocks, bio-binders, organosilane-coated feldspars, safer recycled polymers); (ii) smart monitoring with semi-fixed, wearable and stack sensor units predicting risks via AI-enabled digital twins; and (iii) adaptive protection integrating continuous risk management, human-in-the-loop alerts, and immersive training. Layer 3 ensures systemic validation across 5 pilots (ceramics, foundry, mineral fillers, ELT and plastics recycling), combining TRL6 demonstrations with sustainability, tox/ecotox datasets, techno-economic analysis, and a quantitative SSbD scoring framework. Expected results include ≥30-100% substitution/reduction of hazardous substances ≥50–70% exposure decrease, ≥30 FAIR datasets, ≥200 workers trained with SCORM modules, and the prevention of several hundred premature deaths across pilot validations. By 2035, deployment in 600–800 sites will protect >45,000 workers, avert hundreds of premature deaths annually, cut material and energy intensity by 5–15%, and save 15–20% in compliance costs EU. BRISA advances the green and digital transition, embedding worker protection, circularity, and sustainability into Industry 5.0 pathways.