Respiratory protection

Types of equipment and selection criteria

Filtering equipment may only be used when the atmosphere contains sufficient oxygen (at least 17 percent by volume according to standard criteria), the contaminant is known, and its concentration is compatible with the filter capacity and the equipment’s protection factor. Particle filters are classified as P1, P2, and P3 according to increasing efficiency (filtering facepiece respirators as FFP1, FFP2, and FFP3), and gas and vapor filters by type (A for organic vapors, B for inorganic gases, E for sulfur dioxide and acid gases, K for ammonia, and special types for carbon monoxide, mercury, or nitrogen oxides) and class (1, 2, or 3 according to capacity), with a standardized color code described in INSST NTP 787.

Self-contained breathing apparatus (SCBA) is mandatory when the atmosphere is oxygen-deficient, when the contaminant is unknown, lacks adequate warning properties, or its concentration exceeds the capacity of a filter, and in confined spaces or emergencies involving hazardous atmospheres. Air-line equipment relies on an external source of breathable air of controlled quality; self-contained breathing apparatus provides limited autonomy, determined by the cylinder’s capacity, and requires specific training.

The selection process begins with a risk assessment: identification of the contaminant and its physical form, estimated or measured concentration, applicable exposure limit, oxygen levels, task duration, physical exertion, environmental conditions, compatibility with other PPE, and user characteristics. The equipment’s nominal or assigned protection factor must be sufficient to reduce exposure below the limit value with a margin of safety, and facial fit is crucial for equipment that relies on a tight seal against the face; facial hair, glasses, or an incorrect size negate the protection. The INSST technical guide on PPE and the guidance document on respiratory protection elaborate on these criteria.

Employer obligations and proper use

• Last measure. Royal Decree 773/1997 requires that PPE be used when risks cannot be avoided or sufficiently limited by technical means of collective protection or by measures, methods or procedures of work organization.
• Documented selection. Analysis and evaluation of risks, definition of the characteristics that the equipment must meet, comparison with the performance of available equipment and selection in accordance with marketing regulations, with consultation with the workers.
• Conformity. Equipment with CE marking in accordance with Regulation (EU) 2016/425 as category III PPE, with declaration of conformity and information leaflet from the manufacturer, and filters compatible with the equipment.
• Fit and testing. Check fit before each use and, when the equipment depends on watertightness, qualitative or quantitative fit tests to choose the appropriate model and size for each person.
• Training and information. Theoretical and practical training on risks, equipment limitations, placement, testing, use, maintenance, filter replacement and storage, with practical demonstrations.
• Maintenance and hygiene. Cleaning and disinfection, replacement of filters according to saturation, time or manufacturer’s instructions, inspection of valves and harnesses, protected storage and control of expiration dates; self-contained and air-line equipment require specific maintenance and checks.
• Individual use. The equipment is for personal use unless circumstances require shared use, in which case hygiene and health measures must be adopted.
• Health and fitness monitoring. Consideration of fitness for the use of equipment that involves physiological stress (respiratory resistance, weight, heat stress ), and monitoring of exposed individuals.

Specific situations

• Asbestos and carcinogens. Equipment with a high protection factor in accordance with specific regulations, fit testing, limited usage times and decontamination.
• Silica and dust. FFP2 or FFP3 self-filtering masks or half masks with P2 or P3 filters depending on the exposure, always after technical dust control measures.
• Confined spaces. Prior measurement of oxygen and contaminants, forced ventilation and, when the risk persists, air-line or self-contained breathing apparatus, with external monitoring and rescue.
• Biological agents and healthcare. FFP2 or FFP3 filtering facepiece respirators against biological aerosols, distinct from surgical masks, which are medical devices and not PPE.
• Welding and metal fumes. Equipment with particle filters and, where gases are present, combined filters, or motorized equipment integrated into the welding screen.
• Emergencies and fires. Self-contained breathing apparatus for intervention and short-duration escape equipment for evacuating areas with a risk of gases.

Organizational application: how to manage respiratory protection

1. Identify in the risk assessment the tasks and positions with inhalation exposure that could not be sufficiently controlled and define the type of equipment needed for each one.
2. Select equipment using documented criteria (contaminant, concentration, oxygen, protection factor, duration, compatibility, user characteristics) and consult with workers.
3. Perform fit tests for equipment that depends on facial sealing and assign each person their model and size.
4. Train users with practical demonstrations and record the training; train those responsible for supervising use.
5. Establish the maintenance program: cleaning, filter replacement, inspections, storage and expiration dates, with records for each piece of equipment.
6. Monitor actual usage at workstations and correct deviations (use without adjustment, saturated filters, deteriorated equipment).
7. Review the selection in the event of changes in exposure, products, or the results of measurements and health surveillance.

Preventive management software allows you to associate each job and task with the assigned respiratory protection equipment, record deliveries, fit tests and training, plan filter replacements and inspections, and maintain traceability of each piece of equipment.

Limits and common mistakes

1. Using respiratory protection instead of eliminating or reducing exposure with technical and organizational measures.
2. Use filtering equipment in atmospheres with oxygen deficiency, unknown contaminants, or concentrations exceeding the filter’s capacity.
3. Choosing the type or class of filter without identifying the contaminant, or using particle filters instead of gases and vapors.
4. Ignoring facial fit: hair, glasses, unsuitable sizes, or lack of fit testing.
5. Prolonging the use of saturated or expired filters and neglecting cleaning and storage.
6. Delivering the equipment without practical training or supervision of its use.

The selection, use and maintenance requirements are detailed in Royal Decree 773/1997, in its technical guide and in the INSST’s guidance guide for respiratory protectors; this sheet is for informational purposes.

Regulatory and reference framework

• Royal Decree 773/1997, of May 30. Use by workers of personal protective equipment: selection, use, maintenance, training and consultation.
• Regulation (EU) 2016/425 on personal protective equipment . Marketing requirements and conformity assessment of PPE, including respiratory protection.
• Royal Decree 374/2001, of April 6. Chemical agents; hierarchy of measures and use of PPE as a last resort.
• Technical guide for the use of personal protective equipment by workers (INSST, 2022) . Criteria for the application of Royal Decree 773/1997.
• NTP 787: Respiratory protection equipment: identification of filters according to their types and classes (INSST) . Types, classes and color code of filters.
• Respiratory protection (INSST) . Thematic portal with technical standards, selection guide and documentation.

The UNE-EN standards 149 (self-filtering masks), 140 (half masks), 136 (full-face masks), 143 (particle filters), 14387 (gas and combined filters), 12941 and 12942 (powered equipment) and 137 (self-contained equipment) define the requirements for each type of equipment; Royal Decree 665/1997 and Royal Decree 396/2006 contain specific requirements for carcinogens and asbestos .