Complete Guide to Respiratory Protective Equipment

Respiratory protective equipment (RPE) encompasses a range of personal protective equipment (PPE) designed to protect the wearer’s mouth, nose, and respiratory system. This can include respirators, face masks, helmets, hoods, and visors.

RPE equipment is primarily used to avoid or filter out potentially harmful substances and particles in the air. This can include dust, vapours, mists, gases, and metal fumes. However, since there are various types of RPE mask, some are specially equipped to protect against particular types of airborne contaminants.

There are several different standards for respiratory protection equipment. You can read more about these in the sections below.

European Standards

All RPE types must be fully tested and certified according to European legislation. The European standards (EN) signify that equipment has been tested and meets specific performance requirements. Different standards apply to various types of RPE.

EN136

This standard applies to full face masks. This means any mask which covers the wearer’s eyes, nose, mouth, and chin. It must also either include a respiratory filter or be used as part of a respiratory device. Equipment within this category can be split down further into three categories:

1. Light-duty and low-maintenance
2. Standard-duty with maintainable components
3. Heavy-duty

Class	Durability	Maintenance	Characteristics	Suitable Uses
1	Light-duty	Low maintenance	- Designed for infrequent use - Often disposable	Low danger environments
2	Standard-duty	Maintainable components	- Designed so parts can be cleaned, maintained, or replaced - Manufactured for a longer lifespan than Class 1 masks	Frequent or daily use
3	Heavy-duty	Highest maintenance ability	- Highest levels of protection - Highly durable	Firefighters

EN140

This standard applies to half and quarter masks. Half masks cover the nose, mouth, and chin, whereas quarter masks just cover the mouth and nose. These masks may have a range of materials and filter types, depending on the specific product. If the mask is used as a negative pressure system, the filters must also comply with the relevant standard/s.

EN149

This standard applies to filtering half masks. This means that the mask is either fully or partially made with filter material, or that the filter is not detachable from the remainder of the mask. There are three subcategories within EN149, detailing the different levels of protection. These are:

Class	Filter Penetration	Internal Leakage Rate	Protects Against	Typical Uses
FFP1	Minimum 80% of airborne particles	Maximum 22%	Dust	DIY
FFP2	Minimum 94% of airborne particles	Maximum 8%	Powdered chemicals; some bacteria and viruses	Construction, agriculture, and industry
FFP3	Minimum 99% of airborne particles	Maximum 2%	Very fine particles including asbestos	Medical, high-risk industry

Workplace Exposure Limits

You should also be aware of the EH40 workplace exposure limits (WELs). This applies to approximately 500 defined substances, where set limits have been imposed on the allowable levels of certain hazards in the air.

It is the employer’s responsibility to keep the air contaminate levels as low as reasonably possible below the workplace exposure limit. However, if levels are near or above the WEL, suitable PPE can be used to protect personnel. The protection level of a given respirator is typically stated as a multiple of the workplace exposure limit.

It is essential to ensure that respirators and masks fit correctly and are suitable for use with the hazardous material/s they need to protect against.

How to Wear a Respirator

The following steps detail how to fit and wear a respirator:

• Remove any outer packaging and position the respirator with the nose piece at the top
• Hold the facepiece under your chin with the nose piece over your nose
• Secure the strap/s behind your ears, making sure the respirator does not slip. Take care not to cross or tangle the straps
• If the respirator has a nose clip, press down either side of your nose to meld the nose piece to the shape of your nose
• If air is leaking at the edges of the mask, readjust the straps to achieve a proper seal. If you cannot achieve a proper seal, it may be that a different size is required

If the respirator does not fit properly or you are still experiencing air leakage, do not wear the mask as it will not provide protection. Instead, try a different size mask and ensure it fits properly before exposing yourself to any hazards.

What are the Limitations of Respiratory Protective Equipment?

As with any other form of PPE, respiratory protection equipment does have several limitations. These include:

• Half masks are not suitable for people with full beards as it is not possible to form an effective seal around the face. A powered air system should be used instead
• Full and half mask filters have a finite lifespan. Dust filters can become clogged, whereas a gas mask filter should be changed either after a month of use or immediately if there is a breakthrough (when gas can be detected inside the mask). Special one-use filters should be used and changed after every use when working with gases that have little or no discernible odour
• Disposable masks are suitable for protection against particles like dust only. They will not protect against gases

Respirator filters are designed to remove contaminants and purify the air entering the mask. Different filters and grades are available depending on the type of RPE, the hazard/s, and the severity of the threat. Common respirator filter types include:

Particle Filters

Particulate filters can be categorised in three ways:

Category	Level of Protection	Assigned Protection Factor (APF)	Occupational Exposure Limit (OEL)	Suitable Uses
P1	Low	Materials in concentrations 4x limit	Materials in concentrations 4x limit	Hand sanding, drilling, cutting, aerosols (solid and liquid)
P2	Medium	Materials in concentrations 10x limit	Materials in concentrations 12x limit	Sanding, plastering, dust
P3	High	Materials in concentrations 20x limit	Materials in concentrations 50x limit	Pharmaceuticals, asbestos, bacteria, viruses

What are Occupational Exposure Limits?

Occupational Exposure Limits (OEL) are predetermined higher limits on the adequate concentration of hazardous substances in the air of a workplace. They are typically determined by workplace sampling and analysing historical exposure and workplace health statistics. OELs are enforceable by legislation but can vary between different countries.

Gas and Vapour Filters

Gas and vapour respiratory filters are designed to protect the wearer against hazardous gases and vapour. They can also be separated into distinct classes to determine the efficiency of the filter and the level of protection it offers. These are typically low, medium, and high efficiency.

Combined Filters

Combined filters are designed to protect against particles, gases and vapours simultaneously. However, it is necessary to have an understanding of the air concentration to ensure that a sufficient protection level can be achieved. This can be done in a variety of ways, including using sampling tubes.

Can You Wear Glasses with a Full-Face Respirator?

Glasses should not be worn with full-face respirators as they can impinge on the face seal, meaning potentially harmful particles could be ingested. However, you can wear contact lenses with full-face respirators without incurring any issues. There are several solutions to overcome this issue for those who wear glasses. The most common is to wear a full-face mask with a special corrective glasses insert. This will ensure proper protection and the correct fit, without compromising safety or visibility.

How Many Hours Can You Wear a Respirator?

There is no limit to the duration of time you can wear a respirator. However, if you will be regularly using a respirator or wearing one for prolonged periods (e.g. the duration of a shift), it may be beneficial to consider a powered respirator or supplied air equipment.

What are Dust Masks Made of?

This ultimately depends on the particular mask in question, but the majority of dust masks are made from fine, woven material. Additionally, cartridge gas filters typically contain charcoal, among other materials.