Respiratory Protection Safety Guide

How to Select, Fit and Maintain Respiratory Protective Equipment (RPE)

Breathing safe, clean air in the workplace is a fundamental safety requirement. When airborne hazards cannot be fully eliminated, selecting and using the correct respiratory protection is vital to prevent exposure to dusts, fumes, gases, vapors, or low oxygen environments.

Pre-Use Safety Inspection

• Pre-Use Safety Inspection
  
• Apply higher-level controls first (elimination, substitution, ventilation) before relying on PPE.
  
• Confirm whether respirators are required, and ensure selection is based on the hazard.
  
• Inspect any RPE before use for damage, correct filters, seals, and fit.
  

Tip: RPE is the last line of defence use correct controls upstream first.

Choosing the Right Respirator

Air-purifying respirators are only appropriate where oxygen levels are adequate and contaminants are within the capacity of the respirator. Ensure filters or cartridges match the contaminant type (particulate, gas, vapor) and class. 

 Understanding Standards & Compliance

Respirators used at work must comply with relevant Australian Standards (e.g., AS/NZS 1716:2012 “Respiratory protective devices”, and AS/NZS 1715:2009 “Selection, use and maintenance of respiratory protective equipment”). 

Look for standard numbering on the respirator and packaging.

Employers should implement a formal respiratory protection program when RPE is required.

How to Fit and Wear RPE

Air-purifying respirators (tight fitting):

• Ensure the face is clean-shaven where the respirator seal contacts the face. 
  
• Place the respirator and adjust the head straps so the mask sits snugly and evenly on the face.
  
• Perform a fit-check each time the respirator is donned. 
  
• For half- or full-face reusable models, ensure correct cartridges or filters are installed.
  

Supplied-air or powered respirators:

Follow manufacturer instructions for air supply, hoses, battery checks, and ensure compatibility with the facepiece.

Care, Maintenance & Replacement

• Inspect facepiece, straps, valves, filters, cartridges, and air-supply hoses for damage or wear before each use.
  
• Clean reusable respirators according to manufacturer instructions.
  
• Store respirators in a clean, dry, non-contaminated area, protected from dust, chemicals, and extreme temperatures.
  
• Replace filters/cartridges when breathing resistance increases, when capacity is exceeded, or in accordance with the replacement schedule.
  
• Keep records of maintenance, filter changes, fit testing results (if applicable).
  

Training & Awareness

All workers using RPE must be trained in:

• Identifying when RPE is required and what type is appropriate
  
• Correct donning, doing a fit-check, doffing, and storage
  
• Maintaining and replacing components
  
• Recognizing signs of respirator failure or discomfort
  
• Understanding limitations of RPE and other controls
  

 Quick Daily Check

• Hazards assessed and other controls in place
  
• The correct respirator is selected for the contaminant and exposure level
  
• Facepiece and components are inspected and are in good condition
  
• Fit-check completed and seal confirmed
  
• Filters/cartridges are current and storage compliant
  

Protecting your lungs and airways is non-negotiable. When airborne hazards remain after other controls, correct selection, fit, use, and maintenance of respiratory protection will ensure you breathe safely and maintain compliance.