With major changes to workplace exposure limits coming in 2026, 3M experts share key steps to reassess and upgrade respiratory protection for compliance and safety.
Several occupational exposure limits (OEL) have undergone revisions in recent years, with many limits being reduced to enhance worker health and safety. With the introduction of new workplace exposure limits (WELs) at the end of 2026, many more are being reduced with this being the first major update since the mid 1990’s.
As these standards and limits evolve, it is crucial for organisations to reassess the adequacy of their current respiratory protection to ensure compliance and safeguard employee health as part of their holistic control review.
Workplace exposure standards (WES)/WELs set the maximum allowable concentration of airborne contaminants to protect workers’ health. While generally acceptable for most, some individuals may still experience effects below these levels. Employers must reduce before exposure ‘as low as reasonably practicable’, ideally well below the standard. Lower is always better when it comes to exposure.
Lowering the WES reflects new scientific evidence indicating a need for increasing protection.
An important concept to establish is that respirators do not eliminate exposures, but rather reduce exposures from hazardous levels to acceptable levels when correctly selected, used and maintained.
What is a hazardous level and what is an acceptable level is where the WES/WEL are utilised in the respirator adequacy assessment process. It is the same concept of respirator reduction and use of WES/WEL for all contaminants. The higher the exposure compared to the WES/WEL, the greater the reduction required of the respirator to bring it below the WES/WEL.
Steps can be taken to assess respiratory protection adequacy:
1. Review the new WES/WEL
Identify the specific substances affected and the new exposure standards/limits relevant to your workplace.
2. Confirm/determine exposure levels
Confirming/determining the concentration levels of hazardous substances that have been reduced in your workplace may involve air monitoring and sampling to obtain accurate data on your current exposure levels.
3. Evaluate current respiratory protection level
Assess the current respiratory protection equipment in use for its assigned protection factor (APF)/required minimum protection factor (RMPF), and its suitability for the specific contaminants present. APF/RMPF are based on the wearer doing all the right things; for example, trained, clean shaven and fit testing (when required). Refer to AS/NZS 1715 for APF/RMPF levels.
3. Compare protection levels
Compare the protection offered by the current respirators against the new exposure standard/limits. Ensure the APF/RMPF of the respirators meets or exceeds the level required to maintain exposure below the revised WES/WEL.
4. New product selection
If required, select new/different respirator with higher protection factors to reduce below the revised WES/WEL.
5. Update respiratory protection program
As necessary, update the respiratory protection program to include new respiratory protective equipment, training, and fit-testing procedures. Ensure that all employees are informed and trained on any changes.
Example assessment – Total welding fume
In recent years, the total welding fume WES was reduced from 5mg/m3 to 1mg/m3, a significant reduction. This can be used as an example of assessing the adequacy of a half facepiece respirator with P2 particulate filters for the previous exposure standard to the new one.
Previous exposure standard (5mg/m3 TWA WES)
APF/RMPF of 10 for a half facepiece respirator with P2 filter. This means this respirator/filter combination is adequate for exposures of up to 10 times the WES (5mg/m3), which would be 50mg/m3
Adequate combination protection for this as 20mg/m3 TWA is below the maximum use concentration (MUC) of 50mg/m3 TWA
New/current exposure standard (1mg/m3 TWA WES)
APF/RMPF of 10 for a half facepiece respirator with P2 filter. This means this respirator/filter combination is adequate for exposures of to 10 times the WES (1mg/m³ TWA), which would be 10mg/m3 TWA
Inadequate respirator combination protection for this exposure as 20mg/m3 is above the maximum use concentration (MUC) of 10mg/m3
A different respirator combination must be selected that has an APF/RMPF greater than 20, so the respirator reduction is below (ideally well below) the new exposures standard of 1mg/m3
An example respirator combination that has an APF/RMPF greater than 20 and would be adequate could be a full face with P2 particulate filter (50 APF/RMPF)/P3 particulate filter (100 APF/RMPF) or a powered air purifying respirator (PAPR) with loose fitting headtop and PAPR-P2 or PAPR-P3 particulate filter (APF/RMPF 50). Refer to AS/NZS 1715 for full table of respirator combinations and APF/RMPF.
This is a simple example of reassessing the adequacy of a respirator combination in use and if it is still adequate with a new exposure standard.
There are also many other suitability considerations in addition to the above such as personal protective equipment (PPE) compatibility, comfort, fit/fit testing, facial hair compatibility, communication needs, thermal impact, maintenance, wear time, physical characteristics of the work area, demands of the work, and worker acceptance, to name just a few.
With the introduction of new WELs by the end of 2026, adopting a proactive approach is especially prudent. Stay informed about regulatory developments and emerging research related to occupational exposure. Companies should consider investing in adaptable respiratory protection solutions that can accommodate future changes in standards.
This feature appeared in the September-October edition of Safe to Work.