Complete Guide to Respiratory Protective Equipment

While it is impossible to eliminate every risk in every situation, there is an industry-standard hierarchy of control regarding breathing hazards. Here is the hierarchy ranked from most to least effective:

• Elimination (remove the hazard)
• Substitution (replace the hazard with a less-harmful alternative)
• Engineering controls (remove people from the hazard by improving ventilation, implementing automated processes etc)
• Administrative controls (remove people from the hazard by providing full training, implementing safety signage, changing working patterns etc)
• PPE (provide protection through PPE)

It may come as a surprise that PPE is the least effective method of hazard control, but the key to building an effective solution for managing risk involves working through the hierarchy, top-down, to establish the possibilities. For instance, if it is possible to eliminate the hazard, the steps below won’t be necessary. However, if this is not possible, and the risk of exposure is still present by the time you reach the last step, PPE will be necessary to provide protection.

The hierarchy of control measures is important because many people skip the first four steps and go directly to PPE. While the importance of PPE should not be overlooked, it is also essential to remember that the hazard should always be addressed first if this is an achievable possibility.

Also required under the regulation is confirmation that RPE masks are suitable and fit for purpose. Testing should be carried out to ensure masks are correctly fitted – face fit testing is designed for this.

Face fit testing kits are simply designed to check whether an individual’s mask fits their face size and shape. This ensures compliance and confirms if a particular mask provides suitable protection for the wearer.

Different workplaces and environments require various types of respiratory protection. Industrial locations where respirators may be needed include:

• Agriculture
• Foundries
• Chemical manufacturing facilities
• Construction sites
• Mining operations
• Workshops and automotive repair
• Healthcare facilities
• Pharmaceuticals
• Firefighting
• Waste management and recycling facilities

Additionally, common activities where RPE may be needed include:

• Painting, decorating, spraying, and coating
• Cleaning and maintenance
• Working with resins e.g. resin 3D printers
• Sandblasting
• Working with adhesives
• Welding
• Working with hazardous materials e.g. asbestos
• Woodworking, sanding, and carpentry

It is imperative to ensure that you are fully aware of the potential hazards in the workplace. This will determine the type of RPE needed to guarantee protection whilst working.

Asbestos was a commonly used building material in the past, and many older buildings still contain asbestos today. It is highly dangerous and exposure to asbestos fibres can lead to several serious diseases. As a result, proper protection is vital when working with materials which contain asbestos. Additionally, if you suspect that a building may contain asbestos, you should always take the proper precautions just in case. You should wear either a full or half-face cartridge mask when dealing with asbestos, preferably fitted with a P3 filter. This is a high asbestos mask rating recommended for maximum protection.

When working with chemicals such as paints and glues, you must obtain the material safety data sheet (MSDS) from the manufacturer or point of purchase. This is a requirement under the COSHH regulations and it will inform which types of filter devices are recommended when the chemical is being used.

Mould exposure can cause various health issues, including allergic reactions and respiratory problems. The type of respiratory protective equipment recommended typically depends on the extent of mould exposure. For minor mould cleanup tasks and when exposed to a small amount of mould, an FFP2 mask can provide sufficient protection. However, for more significant mould and areas where mould growth is extensive, either a full or half-face respirator with a P3 filter is recommended.

For smoke, particularly from fires which contain a complex mix of particles, gases, and vapours, a P3 filter is advisable due to the presence of very fine particles. Powered respirators with appropriate filters can also offer higher levels of protection and comfort, especially for prolonged use. However, in environments with very high levels of pollutants or low oxygen levels, self-contained breathing apparatus provides the highest level of respiratory protection. They supply the wearer with clean air from a compressed air cylinder, making them suitable for firefighting and emergency response situations involving smoke.

Carbon monoxide can be extremely hazardous. Therefore, a full-face mask with a carbon monoxide filter or self-contained breathing apparatus is typically recommended for protection in environments where CO levels are elevated or there is a risk of exposure.

With an unpowered respirator, the user draws the air in through the mask’s material (FFP) or filter cartridge. The filtering face piece (FFP) works by removing solid particles as the air is drawn through the material of the mask by the user. Many FFPs have an exhaust valve to prevent condensation inside the mask.

However, FFP masks are not always suitable, depending on the required application, as they can be difficult to seal effectively around the face and the seal may break with flexing or movement. It is important to note that this manual action of drawing the air in can become tiring after a while, which is why powered respirators are often recommended for prolonged periods of use.

A powered respirator features a battery and a blower unit. It sucks air in through a filter and blows it into a headtop, creating a positive pressure atmosphere. This prevents chemicals and dust from accessing the headtop, protecting the worker.

Powered respirators are much more expensive than unpowered respirators, but they are also much more comfortable to wear over prolonged periods. Powered respirator batteries typically last approximately 8 hours, making them ideal for wearing during shift work. Many models also include a variety of respirator filters that can be fitted to protect against dust, gases, or a combination of other hazards.

A supplied-air respirator or air-fed helmet is similar to a powered respirator. However, instead of a blower and battery, the equipment is hooked up to a compressed air system.

This can be limiting as it restricts movement, but there is no chance of the battery going flat or the blower breaking, which may happen with powered respirators over prolonged periods. Supplied air respirator hoses typically include special filter units to clean the air, remove any oil or contaminants, and ensure the air is breathable.

A respiratory helmet, air hood respirator, or visor respirator can be beneficial in some scenarios. Primarily used when welding, helmet respirators are designed to protect against fine oxide dust particles generated through the welding process.

These particles can cause metal fume fever, so it is important to be fully protected. Powered headtops with welding glass screens are also suitable specialist respiratory protective equipment for welding.

Protective hoods cover the head, neck, and sometimes shoulders, protecting the wearer from hazardous substances in the air. These hoods can be made from various materials, including silicone, PVC, and polyester, to ensure they provide adequate protection against the specific hazards present in the wearer's environment.

Safety hoods are reusable and durable and can typically be decontaminated after use. They often include clear visors or face shields for added visibility.