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Respiratory Protective Equipment (RPE) is a critical layer of defence for workers exposed to airborne hazards like dust, fumes, vapours, But not all RPE offers equal protection, and even the best equipment won’t keep you safe if it doesn’t fit properly, isn’t suited to the task and things it’s filtering, or isn’t well maintained.

Here’s what you need to know about getting RPE right, from upfront fit testing to choosing the right cartridges, to regular check-ups and health monitoring.

Step 1: Get Fit-Tested – One Size Doesn’t Fit All

Before a worker ever steps into a hazardous area, they need to be fit tested for the right RPE. Why? Because no two faces are the same. RPE comes in different sizes typically ranging from Small to Extra Large, and a poor fit can mean poor protection, even if the mask looks like it fits.

Key considerations:

• Fit testing is essential for “negative pressure” RPE like half-face or full-face respirators.
• Fit testing ensures that the mask seals properly and provides effective protection.
• Facial hair, even stubble, will destroy that seal. If workers choose to keep facial hair, consider positive pressure powered respirators that don’t rely on a tight face fit. But be aware they carry more cost and size.

Fit testing must be:

• Conducted before first use of RPE.
• A fit test should be repeated whenever there is a change to the RPE type, size, model or material or whenever there is a change to the circumstances of the wearer that could alter the fit of the RPE; for example:
  • Weight loss or gain;
  • Substantial dental work;
  • Facial changes (scars, moles, effects of ageing etc)
  • Facial piercings;
  • Introduction or change in other head-worn personal protective equipment (PPE).
• This is done with qualitative (using taste or smell) and quantitative (using specialised equipment), and is performed by a competent person trained and certified in how to do it. Competence can be demonstrated by accreditation under the Fit2Fit RPE Fit Test Providers Accreditation Scheme

Fit testing is also a great opportunity to train workers on how to wear and check their masks properly, which brings us to the next step.

Step 2: Choose the Right RPE for the Risk

Not all filters protect against all hazards. It’s essential to choose RPE that’s targeted to the type of contaminant and the task at hand.

Types of RPE include:

• Disposable respirators -In reality you will struggle to convince WorkSafe that this is ok, as even disposable masks have to be fit tested according to the standards, so you are far better off skipping these for better protection.
• Reusable half- or full-face respirators (negative pressure systems) – used with interchangeable cartridges that target specific hazards.
• Powered Air Purifying Respirators (PAPRs – Positive pressure systems) – provide more filtered air than you can breathe to keep any contaminants away from your breathing zone, these can be more comfortable for long term wear as they keep fresh air moving over you.
• Supplied air respirators – used only in high-risk environments where there isn’t oxygen in the atmosphere, they can be “supplied” which uses a compressed air line to the set or a “self contained” system like you see fire fighters use.

To get this right, consider:

• What is the form of the contaminant? Dust, gas, mist, or vapour? Each requires a different filter or cartridge type.
• What do the Safety Data Sheets say? (SDS) Can you get an SDS for the substances you’re working with? And what do they recommend?
• What level of activity is involved? Light vs heavy work, short vs extended durations, confined spaces – all affect your choice of gear.
• Is the RPE compatible with other PPE (like safety glasses, helmets, or earmuffs)? Full face respirators are far better than half face ones as they also protect your eyes from the dust and chemicals.
• What level of comfort is needed? If RPE is uncomfortable, workers are less likely to wear it correctly or consistently.

Important: Choosing the wrong size or type of RPE will give the illusion of safety, while leaving workers dangerously exposed. There is a world of difference between “looks safe” and “is safe”

Step 3: Maintain the Protection Over Time

Once the right gear is chosen and correctly fitted, the work doesn’t stop. RPE needs to be maintained, checked, and re-evaluated regularly.

What ongoing checks are needed?

Daily visual inspections
Before each use, workers should inspect their gear for cracks, tears, wear, or contamination. Damaged RPE should not be used.

Filter and cartridge replacement
There’s no one-size-fits-all rule for changing filters – check with your manufacturer. Never rely on smell or taste to know if filters are still working – by the time you smell something, it is already damaging you.

Regular fit testing
Our faces change over time. Even subtle shifts in weight or facial structure can impact the mask’s seal. Fit2fit recommends that fit testing should be conducted at least every 2 years.

Proper cleaning and storage
Dirty or improperly stored RPE may not perform when needed. Train workers on cleaning routines and ensure hygienic storage.

Don’t Skip Health Monitoring

Even with the best gear, health monitoring plays an essential role in a full respiratory protection programme. It’s how you check whether control measures (like RPE) are really working, and catch signs of harm early.

Under The Control of Substances Hazardous to Health Regulations 2002 , you’re required to monitor workers’ health if they’re exposed to substances that pose a serious health risk.

Health surveilance can include:

• Initial screening questionnaire to identify potential health concerns.
• Lung function tests
• Regular checks if there’s known long-term exposure to hazardous substances.
• Investigations if symptoms or health concerns arise.

Final Thoughts: Protecting People, Not Just Ticking Boxes

RPE isn’t just a piece of kit,  it’s a commitment to keeping people safe. By following these three steps:

1. Upfront fit testing
2. Choosing the right RPE and cartridges for the job
3. Ongoing maintenance and health checks 

You’re doing more than following regulations. You’re creating a culture where safety is personal, proactive, and properly managed.

The right mask, worn the right way, backed by the right training and monitoring – that’s how you keep your team safe.