I just wanted to pop in to comment on the original post way way back there, lol
I too converted from shavings to sand in the coop about 3 months ago. Ohhh how I loved it at first. 5 minutes every day scooping the poo out and it was as good as new. I kept shavings on the poop board and in the nest boxes. 15 dollars for a ton of sand on the floor and refilling it might cost me a whole 10 dollars a year, and I never have to worry about the girls having grit.
Now I find though (just like the OP) that the dust is really irritating, the smell is getting worse, if I dont scoop every single day then I triple my time the next day, and oddly enough i miss the smell of pine shavings.
I have just recently decided to go to more of a hybrid system. I am going to widen my poop boards slightly to catch that little bit that gets by them, I am shoveling that ton of sand into the run for grit and dust baths, I am going back to deep litter pine, and I will put new (washed) sand mixed with PDZ on the poop boards. I really feel I will get the better of both worlds with this solution.
I have been doing this for a while now and it is amazing how much I continue to learn.....