FUSION Issue 1 2026 DIGITAL SINGLE PAGES - Flipbook - Page 21
RESPIRATORY PROTECTION IN PAINTSHOPS
Are You Actually
Compliant?
Most paintshops still
treat masks as generic
PPE. HSE doesn’t, and the
consequences of getting
it wrong go far beyond a
warning notice.
Walk into any paintshop and
you’ll likely see the same thing:
workers grabbing whatever mask
is available, wearing it until it’s
uncomfortable, then moving on.
But when solvents, isocyanates,
and coating vapours are in the air,
that casual approach creates legal
exposure, operational risk, and real
health consequences.
Here’s what compliance actually
looks like.
RPE is your last
line of defence –
not your first
COSHH regulations are clear:
respiratory protection should only be
used when other controls fail. HSE
expects you to eliminate hazards,
substitute safer materials, or engineer
controls before issuing masks.
If you’re reaching for RPE without
exhausting those options first, your
risk assessment is incomplete.
One mask does
not fit all tasks
The real cost of
non-compliance
Particulate filters don’t protect
against solvent vapours. Organic
vapour filters may be inadequate
for isocyanates. Confined marine
spaces often require air-fed
systems, not standard negative
pressure masks.
Getting respiratory protection
wrong doesn’t just invite
enforcement action. It causes
immediate health effects,
long-term occupational illness,
compensation claims, and the loss
of skilled workers.
Using the wrong mask isn’t a minor
error. It’s a control failure. And
if an incident occurs, “we didn’t
know” won’t stand up.
Operationally, incidents disrupt
production and undermine
workforce trust. From a leadership
perspective, inadequate protection
represents a fundamental failure of
duty of care.
Face fit testing
is mandatory,
not optional
Tight-fitting masks require
face fit testing. This is a legal
requirement under COSHH, not a
recommendation.
Without proper fit testing, even
the highest-spec filter provides
limited protection. Facial hair,
weight changes, and switching
mask models all affect seal quality,
and all require retesting.
Training and
maintenance aren’t
afterthoughts
Selecting the right mask is
only half the job. Filters expire.
Masks degrade. Poor storage
compromises performance.
Workers need to understand
why a specific mask is required,
how to fit it correctly, and when
not to use it. Uncomfortable or
poorly chosen equipment leads to
non-compliance, especially in hot,
demanding environments where
shortcuts become tempting.
What compliance
actually looks like
High-performing operations build
respiratory protection into process
design from the start:
• Task-specific risk assessments
that match hazards to
protection levels
• Documented face fit testing
with regular review schedules
• Proper maintenance, storage,
and replacement protocols
• Comprehensive training that
explains the “why,” not just
the “what”
In environments where coatings
and surface preparation are critical
to quality, protecting the people
doing that work isn’t optional.
HSE requirements are clear.
The challenge is applying them
consistently and with the
seriousness they deserve.
“ Respiratory
protection is
not the first line
of defence it’s what you
use when
everything else
has been tried. ”
Your respiratory
protection
program may
be failing if:
1. Workers are using the same
mask type for multiple
different tasks.
2. Face fit testing hasn’t been
done in the past 12 months.
3. Filters are being used
beyond their service life or
“until they smell bad”.
4. Facial hair policies aren’t
enforced for tight-fitting
masks.
5. Workers can’t explain why
they’re using a specific mask
for their task.
NEED TO
REVIEW YOUR
RPE PROGRAM?
Start with your COSHH
risk assessments.
Are they task-specific?
Do they consider all
exposure routes? Have
controls been prioritised
correctly, with RPE as
the last resort?
If you’re unsure,
it’s time for an
independent review.
dtc-uk.com
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