When Should RPE Be Used?

RPE may be required when:

• Engineering controls cannot adequately control the remaining exposure.
• Additional protection is required while using on-tool extraction or water suppression.
• Maintenance or cleaning temporarily increases the risk of exposure.
• Workers must enter an area where residual hazardous dust may remain.
• Emergency or unexpected conditions affect the normal controls.

RPE should not be used as a substitute for effective on-tool extraction, water suppression, local exhaust ventilation or other reasonably practicable controls.

Selecting Suitable RPE for Silica Dust

RPE must be both adequate and suitable. Adequate means it provides sufficient protection against the identified hazard. Suitable means it is appropriate for the wearer, task, environment and other protective equipment being used.

The COSHH risk assessment should consider:

• The type and concentration of hazardous dust.
• The required assigned protection factor.
• The duration and physical demands of the task.
• Whether the work is undertaken in a hot, enclosed or restricted area.
• The worker's facial characteristics and ability to wear the equipment.
• Compatibility with eye, hearing, head and face protection.

A filter marked FFP3 or P3 does not automatically make the complete RPE suitable for every task. The complete respirator must provide the protection identified by the risk assessment.

Common Types of RPE for Silica Dust

Disposable FFP3 Respirators

A disposable FFP3 respirator may be suitable for certain short-duration tasks involving fine hazardous dust. It is a tight-fitting facepiece and must form an effective seal around the wearer's nose and mouth.

Reusable Half-Mask Respirators

A reusable half-mask fitted with appropriate P3 particulate filters may be selected for work involving silica dust. The mask and filters must be compatible and used in accordance with the manufacturer's instructions.

Full-Face Respirators

A full-face respirator may provide respiratory, eye and face protection. If it relies on a tight seal against the face, the wearer must be clean-shaven in the sealing area and pass an appropriate face-fit test.

Powered Respirators

Powered respirators use a motorised fan to supply filtered air. They may be suitable for longer or more physically demanding tasks, or where a higher level of protection is identified as necessary.

Loose-fitting powered hoods or helmets may provide an alternative for people who cannot achieve a reliable seal with tight-fitting RPE, including workers with facial hair for religious, medical or other reasons.

Face-Fit Testing for Tight-Fitting RPE

Anyone required to wear tight-fitting RPE must undergo face-fit testing for the particular make, model, type and size of facepiece they will use.

People have different facial shapes and sizes, so one respirator will not necessarily fit every worker. Face-fit testing confirms whether the selected facepiece can form an adequate seal on that individual.

If a worker uses more than one type of tight-fitting facepiece, each type must be fit tested. A new test may also be necessary when the facepiece changes or when a significant change to the wearer's face could affect the fit.

Face-fit testing must be carried out by a competent person. Passing a fit test does not remove the need to put the respirator on correctly and check its seal every time it is worn.

Facial Hair and Respirator Seals

Tight-fitting RPE relies on direct contact between the mask and the wearer's skin. Beards, stubble and other facial hair in the sealing area can create gaps that allow contaminated air to enter.

Workers using tight-fitting RPE must be clean-shaven wherever the facepiece seals against the face. Even short stubble can interfere with the seal.

Where a worker cannot be clean-shaven, suitable RPE that does not depend on a tight facial seal should be considered, such as an appropriate powered hood or helmet.

Putting On and Checking a Respirator

Before entering a dusty area, the wearer should ensure that:

• The mask is the same make, model, type and size used for the successful face-fit test.
• The respirator and filters are suitable for the task.
• The mask is clean and free from damage.
• The straps are correctly positioned and adjusted.
• The facepiece covers both the nose and mouth.
• The filters are correctly fitted and within their service life.
• Other PPE does not interfere with the mask's seal.
• A pre-use seal check is completed in accordance with the manufacturer's instructions.

A pre-use seal check must be completed every time tight-fitting RPE is worn, but it does not replace formal face-fit testing.

Common RPE Problems

RPE may provide inadequate protection when:

• The facepiece is the wrong size or shape for the wearer.
• Facial hair breaks the seal.
• The straps are loose, twisted or incorrectly positioned.
• The mask is worn below the nose.
• The facepiece, valves or filters are damaged.
• Filters are incorrectly fitted, blocked or unsuitable.
• Safety glasses, goggles or other PPE interfere with the seal.
• The wearer has not been trained or face-fit tested.

A worker should leave the contaminated area and report the problem if the respirator becomes damaged, breathing becomes unusually difficult or there is reason to believe that protection has been lost.

Cleaning, Maintaining and Storing Reusable RPE

Reusable respirators must be cleaned, examined, maintained and stored in accordance with the manufacturer's instructions.

Maintenance should include:

• Cleaning and disinfecting the facepiece as required.
• Inspecting straps, seals, valves and connectors.
• Replacing damaged or worn components.
• Replacing filters at the appropriate time.
• Checking batteries and airflow on powered equipment.
• Keeping suitable maintenance records where required.

Clean RPE should be stored in a suitable container or designated area that protects it from dust, moisture, sunlight, contamination and physical damage.

Replacing Disposable FFP3 Respirators

Disposable respirators should be replaced when they:

• Become dirty or contaminated.
• Are damaged or misshapen.
• Become wet.
• Become difficult to breathe through.
• No longer form an effective seal.
• Reach the end of the manufacturer's specified period of use.

Disposable RPE must not be cleaned or reused unless the manufacturer specifically confirms that the product is designed for reuse.

Eye and Face Protection

Dust can irritate or damage the eyes, particularly during cutting, drilling, grinding and demolition. Suitable eye or face protection may therefore be required in addition to RPE.

Safety glasses, goggles and visors must be compatible with the selected respirator. They must not disturb a tight-fitting facepiece or create gaps around its seal.

Powered respirators with integrated visors may provide combined respiratory, eye and face protection where they are suitable for the task and hazard.

RPE as Part of a Complete Silica Dust Control System

Masks protect individual wearers, but they do not remove dust from the environment or protect unmasked people nearby. Employers must continue to control dust at its source and prevent it from spreading.

An effective silica dust control system may combine:

• Elimination or substitution.
• On-tool dust extraction.
• Water suppression.
• Local exhaust ventilation.
• Exclusion zones and safe working procedures.
• Suitable housekeeping and waste disposal.
• Appropriate RPE for residual exposure.
• Training, supervision and regular monitoring.

RPE is only effective when it is correctly selected, face-fit tested where necessary, properly worn, maintained and used alongside effective dust controls.