The rules for respiratory protection go beyond putting on any protective mask. For protection to be effective, the equipment must match the specific risk, fit the face properly and be maintained and replaced according to the manufacturer's instructions.
The wrong filter, an incorrectly fitted mask or gaps between it and the face can significantly reduce protection. This applies even when the product is of good quality and carries the necessary marking.
That is why choosing suitable respiratory protection equipment should be part of the overall assessment and reduction of risk in the workplace.
When Is Respiratory Protection Needed?
Respiratory protection equipment is used when workers may be exposed to:
- dust and fine particles;
- smoke and metal fumes;
- liquid or oil aerosols;
- organic vapors;
- acid or inorganic gases;
- ammonia and its derivatives;
- biological agents;
- other hazardous substances that can be inhaled.
Before a mask or respirator is chosen, the type of contaminant, its concentration, the duration of exposure and the conditions in which the work will be done must be established.
Personal protective equipment does not replace other safety measures. Where possible, contamination should be limited through ventilation, local extraction, enclosing the process or changing how work is organized.
How Is the Right Equipment Chosen?
There is no universal mask that protects against all types of dust, gases, vapors and aerosols at once. The first step is to identify the specific hazard.
Identify the type of contaminant
Contaminants can be broadly divided into:
- particles - dust, fibers, smoke and aerosols;
- gases and vapors;
- a combination of particles, gases and vapors.
Filtering masks and respirators with filters clean the air from the work environment. They do not supply oxygen and are not suitable for use where there is a lack of oxygen, an unknown atmosphere or conditions immediately dangerous to life.
Determine the level of protection needed
Filtering half masks to EN 149 use the following classes:
- FFP1 - the lowest of the three levels of protection against particles;
- FFP2 - a higher degree of filtration;
- FFP3 - the highest class within the EN 149 standard.
The FFP class should not be chosen just by how dusty the environment looks. The type and concentration of the particles, the exposure time and the level of protection needed all matter.
Filtering half masks against particles do not automatically protect against gases and chemical vapors.
Choose the right filter
With reusable masks, the filter must match the specific contaminant.
| Marking | Main purpose |
|---|---|
| P1, P2, P3 | Particles requiring different levels of protection |
| A | Certain organic gases and vapors |
| B | Certain inorganic gases and vapors |
| E | Sulfur dioxide and certain acid gases |
| K | Ammonia and certain derivatives |
| Combined filter | A specified combination of gases, vapors and particles |
The letter or color on the filter is not enough to choose it. The full marking, class, compatibility with the mask and the manufacturer's technical documentation must be checked.
The specific suitability of the filter is also checked against the safety data sheet of the substance used. A particle filter must not be used in place of a gas and vapor filter.
Check compatibility with other PPE
The mask must be usable together with any required:
- safety glasses;
- face shields;
- helmets;
- earmuffs;
- welding helmets;
- protective clothing.
The frames of glasses, helmet straps or other elements must not come between the mask and the face and break its seal.
What Are the Main Types of Respiratory Protection Equipment?
Filtering half mask
With this type of equipment, the mask material itself filters the air. Filtering half masks are usually used against particles and may be marked FFP1, FFP2 or FFP3.
The marking may include:
- NR - intended for use within a single work shift;
- R - can be reused under the manufacturer's conditions;
- D - has passed an additional clogging test.
The R marking does not mean unlimited use. The condition of the mask must be checked before each fitting.
Half mask with replaceable filters
A half mask covers the nose, mouth and chin. Filters for particles, gases and vapors or combined filters can be fitted to it.
The facepiece can be used repeatedly, but the seal, valves, straps and filter connections must be checked.
Full-face mask
A full-face mask covers the eyes, nose, mouth and chin. It can provide respiratory protection and eye and face protection at the same time.
However, greater coverage does not mean that every model or filter is suitable for every work environment. The choice again depends on the identified risk.
Correct Fitting and Seal Checks
A tight-fitting mask must form a continuous seal against the face. If gaps remain, some of the contaminated air can pass around the filter.
The exact instructions depend on the model, but the general sequence includes:
- Checking the mask and filters for damage, contamination or deformation.
- Confirming that the right model, size and filter have been chosen.
- Placing the mask over the nose, mouth and chin.
- Positioning the straps correctly around the head.
- Tightening them evenly, without distorting the mask.
- Shaping the nose clip, if the model has one.
- Checking the seal before entering the contaminated area.
The mask must not be worn under the nose, over the mouth only or with loose straps.
Check every time you put it on
The user must carry out the check specified by the manufacturer every time a tight-fitting mask is put on.
This check shows whether there is obvious air leakage around the facepiece at that moment. It is not the same as a fit test, which establishes whether a specific model and size are suitable for a particular person.
The effect of a beard
There must be no beard, stubble, sideburns or other hair in the facial seal area that interferes with contact between the mask and the skin.
Hair can create gaps and let contaminated air pass the filter. When a tight fit cannot be ensured, suitable equipment that does not rely on this type of facial seal must be chosen.
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When Should the Mask and Filters Be Replaced?
Masks and filters do not have the same service life. Replacement depends on the type of equipment, the contaminant, working conditions and the manufacturer's instructions.
Filtering half masks
The mask must be replaced when:
- it is damaged or deformed;
- it is visibly dirty;
- it does not fit properly;
- the straps are torn or stretched;
- breathing through it has become noticeably harder;
- it is very damp;
- the manufacturer's usage limit has been reached.
A mask marked NR must not be used as equipment for unlimited repeated use.
Particle filters
Particle filters gradually build up contamination. They are replaced when there is:
- increased breathing resistance;
- visible contamination;
- mechanical damage;
- wetting;
- incorrect storage;
- an expired shelf life;
- the limit set by the manufacturer has been reached.
Do not wait for the filter to become completely clogged.
Gas and vapor filters
The service life of gas and vapor filters depends on:
- the type and concentration of the substance;
- temperature and humidity;
- physical exertion;
- the filter's capacity;
- the duration of use;
- how it is stored after opening.
Replacement must not be based solely on detecting a smell or taste. Some substances have no reliable warning properties, and people's sensitivity varies.
A predetermined schedule must be used, based on the manufacturer's instructions and the working conditions. Suitable mask filters are chosen not only according to the mask model but also according to the specific contaminant.
How Do You Check a Reusable Mask?
Before each use, check:
- the mask body;
- the facial seal;
- the straps and buckles;
- the inhalation and exhalation valves;
- the filter connections;
- the visor on full-face models;
- the filters and their marking.
The mask must not be used if there are cracks, deformation, missing parts, damaged valves or a problem with how the filters are attached.
If contaminant penetration, difficulty breathing, shifting or a broken seal is felt during work, the worker must leave the contaminated area and check the equipment.
Cleaning and Storage
Reusable masks are cleaned and disinfected according to the manufacturer's instructions.
The basic rules include:
- removing the filters when the procedure requires it;
- not using products that can damage the material;
- checking the valves and seal after cleaning;
- drying the mask completely;
- storing it in clean, closed packaging;
- protecting it from dust, chemicals, sunlight and deformation.
Gas and vapor filters can continue to absorb substances from the surrounding air even when not in use. That is why closing and storing them properly after opening is important for their service life.
The Most Common Mistakes in Respiratory Protection
Among the most common mistakes are:
- choosing a mask without identifying the contaminant;
- using a particle filter against gases and vapors;
- wearing the mask under the nose;
- wearing it over a beard in the seal area;
- skipping the check after putting it on;
- using one model and size for all employees;
- loose or twisted straps;
- glasses or a helmet that break the seal;
- replacing a gas filter only after noticing a smell;
- reusing a damaged or heavily contaminated mask;
- storing the mask uncovered in a contaminated room;
- no training in use and maintenance.
Compliance with a particular standard is not enough if the equipment is not suited to the specific risk and is not used correctly.
What Markings Should Be Checked?
Depending on the product, the following should be checked on the mask, filter or packaging:
- the CE marking;
- the applicable European standard;
- the protection class;
- the filter type and class;
- the R, NR and D markings, where applicable;
- the manufacturer and model;
- the shelf life;
- the limitations of use.
The CE marking shows compliance with the applicable requirements for the product. However, it does not mean that a particular mask is suitable for every contaminant, user or work task.
Conclusion
The rules for respiratory protection start with identifying the risk and choosing equipment suited to the specific contaminant and working conditions.
The mask must fit the face properly and be checked every time it is put on. A beard in the seal area, the wrong size, loose straps or incompatible glasses can significantly reduce protection.
Filtering masks, particle filters and gas filters have different rules for use and replacement. They must not continue to be used if they are damaged, contaminated, make breathing difficult or have reached the specified limit.
Effective respiratory protection depends not only on the quality of the product but also on correct choice, fitting, checking, maintenance and timely replacement.