Respiratory Protection

Respiratory protection is a type of personal protective equipment (PPE) designed to ensure safe breathing when the air in the workplace contains harmful substances. The goal is to ensure that only clean air is inhaled.

According to the European PPE Regulation (EU) 2016/425, respiratory protection falls under Category III, the highest risk class. This means that strict requirements apply to certification, product inspection, and proper use. Proper selection and correct use are essential to prevent serious injury.

When is respiratory protection needed?

Normal air consists of approximately 21% oxygen. Respiratory protection is required when other measures, such as source control or ventilation, do not provide sufficient protection.

As long as exposure to hazardous substances remains below the applicable exposure limits, respiratory protection is not required. Exceeding these limits means that additional measures are necessary.

Exposure limits are typically determined over an eight-hour workday and expressed in ppm, mg/m³, or v/m³.

RI&E and Occupational Hygiene Approach

The need for respiratory protection always stems from the Risk Inventory and Evaluation (RI&E). Organizations where work involves chemical, biological, or physical substances must have an occupational hygiene program in place.

This program includes:

• Exposure measurements and assessments
• Documentation of measures in accordance with the occupational hygiene strategy
• An up-to-date list of substances used, including safety information

The use of respiratory protection is specified in the action plan. Often, a prevention officer or safety specialist checks in advance whether the chosen equipment provides adequate protection.

Dependent and independent respiratory protection

Respiratory protection is divided into two main groups.

Powered air-purifying respirators

With dependent respiratory protection, the ambient air is filtered. This is done using masks and filters that block dust particles, gases, or vapors. The level of protection depends on:

• The type of filter
• The fit of the mask
• The concentration of the contaminant

These devices are suitable as long as there is sufficient oxygen and the concentrations are known and controllable.

Self-contained respiratory protection

With self-contained breathing apparatus, clean air is supplied from compressed air cylinders or a compressor. The user therefore does not breathe in ambient air.

This type of protection is required when:

• Less than 19% oxygen
• Unknown or high concentrations of hazardous substances
• Confined spaces
• Situations such as asbestos or sewer fumes

Self-contained systems offer a very high level of protection, but their operating time is limited by the available breathing air.

Types of respiratory protection equipment

Dust masks (FFP)

Dust masks are intended for single-use or limited use and cover the nose, mouth, and chin.

• FFP1: low dust exposure
• FFP2: harmful fine particulate matter
• FFP3: toxic fine dust, highest level of protection

Additional markings indicate whether the mask has a valve or is reusable.

Half-face masks

A half-face mask covers the nose, mouth, and chin and uses replaceable filters. Models with two filters often have lower breathing resistance.

These masks protect against dust, gases, and vapors. Be aware of potential skin reactions and, if necessary, choose hypoallergenic or silicone materials.

Full-face masks

A full-face mask also covers the eyes and therefore offers a higher level of protection. They are equipped with a speaking valve for communication.

Full-face masks can be used with:

• Filters
• Breathing apparatus
• Breathing air supply networks

The service life depends on the level of contamination and the filter load.

Filters and combination filters

Gas and Particle Filters

Gas filters capture gases and vapors and are combined with particulate filters (P1, P2, or P3). The higher the filter class, the greater the protection capacity.

Filters are coded according to EN 14387, with color and letter designations for specific substances.

Combination filters

Combination filters are used when both dust and gases are present, such as ABEK filters. These filters have a limited service life and should not be reused indefinitely.

Special filters are available for specific substances such as mercury, carbon monoxide, or radioactive iodine. If the filter emits an odor or taste of contamination, it must be replaced immediately.

Motor-powered respiratory protection

In motor-powered systems, filtered air is actively supplied to a mask, hood, or helmet. This reduces breathing resistance and increases comfort.

These systems are widely used in environments with high dust levels or during prolonged work.

Fit and fit testing

A proper fit is crucial. Before use, always check that the mask is clean, undamaged, and forms a tight seal.

Facial hair can compromise the seal and is therefore not permitted with tight-fitting masks. In high-risk applications, a Face Fit Test is performed to assess leakage and protection.

Maintenance and Storage

Respiratory protective equipment must be:

• Cleaned and disinfected
• Dried and tested
• Properly stored and labeled

Used filters and masks are collected as chemical waste. Proper instruction on maintenance and storage is essential to ensure safe use.

Good Employment Practices

Good employment practices mean ensuring safe working conditions and the health of employees. Employers can offer medical fitness assessments to determine whether someone can safely work while wearing respiratory protection.

For certain roles, such as firefighters, these examinations are required by law. In all cases, risks and the associated PPE must be clearly documented in the RI&E.

Coordination and Assurance

Effective respiratory protection requires collaboration between the employer, the safety officer, the occupational health and safety service, the supplier, and the user—from measurements and selection to instruction, supervision, and periodic evaluation.

By properly organizing this chain, protection remains reliable and the risk of health damage is demonstrably reduced.