Product Overview

Summary: This Respiratory Protection Safe Operating Procedure provides a clear, practical framework for selecting, using, fitting and maintaining respirators in Australian workplaces. It supports compliance with WHS laws while protecting workers from airborne contaminants such as dusts, fumes, mists, gases, vapours and biological hazards across a wide range of industries.

Airborne contaminants remain one of the most common and serious health risks in Australian workplaces, contributing to occupational lung disease, asthma, cancer and long-term disability. This Respiratory Protection Safe Operating Procedure translates complex regulatory and technical requirements into a practical, step-by-step system that can be implemented on any site where dusts, fumes, mists, gases, vapours or biological agents may be present. It sets out how to identify when respiratory protective equipment (RPE) is required, how to choose the right type of respirator for the hazard, and how to ensure every worker is properly fitted, trained and medically able to wear it.

The procedure is designed to help businesses build a defensible respiratory protection program aligned with Australian WHS legislation and key standards such as AS/NZS 1715 and AS/NZS 1716. It addresses real-world challenges like inconsistent mask use, poor storage and maintenance, inadequate fit testing, language and literacy barriers, and contractor management. By implementing this SOP, organisations can reduce the risk of occupational disease claims, demonstrate due diligence to regulators and clients, and give workers confidence that their health is being actively protected every shift.

The document is suitable for a broad range of industries, including construction, manufacturing, mining, agriculture, healthcare, laboratories, waste management and emergency services. It includes templates and guidance that can be adapted to both small businesses and large multi-site operations, ensuring a consistent approach to respiratory protection across the entire workforce, including contractors, visitors and labour hire personnel.

Key Benefits

• Ensure consistent selection, fit testing, use and maintenance of respiratory protective equipment across all worksites.
• Reduce the risk of occupational lung disease, respiratory irritation and long-term health claims arising from airborne contaminants.
• Demonstrate due diligence and compliance with Australian WHS legislation, relevant Codes of Practice and AS/NZS standards.
• Standardise training and supervision expectations so workers, supervisors and contractors clearly understand their responsibilities.
• Improve audit readiness by documenting a clear, repeatable respiratory protection process supported by checklists and records.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Site Supervisors
• Construction Project Managers
• Manufacturing and Production Managers
• Laboratory Managers
• Maintenance Supervisors
• Warehouse and Logistics Managers
• Mining and Resources Supervisors
• Healthcare and Aged Care Managers

Hazards Addressed

• Inhalation of respirable crystalline silica dust (e.g. from cutting, grinding, drilling concrete or stone)
• Exposure to welding fumes and metal fumes (e.g. manganese, hexavalent chromium)
• Inhalation of asbestos fibres during disturbance of legacy materials
• Exposure to organic vapours and gases (e.g. solvents, paints, adhesives, pesticides)
• Inhalation of hazardous chemical mists and aerosols (e.g. cleaning agents, disinfectants, acids, alkalis)
• Biological aerosol exposure (e.g. viruses, bacteria, moulds in healthcare, laboratories, waste handling)
• Wood dust, grain dust and other allergenic or sensitising dusts
• Combustion products and smoke during hot work or emergency response
• Nuisance dusts that may aggravate asthma and other pre-existing respiratory conditions

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, Contractors)
• 4.0 Regulatory and Standards Reference
• 5.0 Hazard Identification and Airborne Contaminant Assessment
• 6.0 Hierarchy of Control and When RPE is Required
• 7.0 Selection of Appropriate Respiratory Protective Equipment
• 8.0 Fit Testing, Fit Checking and Facial Hair Requirements
• 9.0 Training, Competency and Information for Workers
• 10.0 Pre-use Inspection and Donning/Doffing Procedure
• 11.0 Safe Use of Respirators During Work Activities
• 12.0 Cleaning, Decontamination, Storage and Maintenance
• 13.0 Medical Considerations and Fitness to Wear RPE
• 14.0 Contractor and Visitor Management for Respiratory Protection
• 15.0 Emergency Situations and Use of Respirators in Incidents
• 16.0 Recordkeeping, Auditing and Continuous Improvement
• 17.0 Document Control and Review

Legislation & References

• Model Work Health and Safety Act
• Model Work Health and Safety Regulations – Part 3.2 (General workplace management) and Part 7.1 (Hazardous chemicals)
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risks of Airborne Contaminants at the Workplace (where adopted or referenced by regulators)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 45001 (or AS/NZS 4801): Occupational health and safety management systems
• Relevant state and territory WHS/OHS regulations and guidance material (e.g. respirable crystalline silica, welding fumes, asbestos)