Respiratory protection at work in Germany: selection, health checks and rules of use

When is respiratory protection needed?

Respiratory protection is needed if, despite technical and organisational measures, employees could inhale hazardous substances, biological agents or dusts in harmful concentrations or if there is a risk of oxygen deficiency. The risk assessment (Gefährdungsbeurteilung) shows whether a device is needed and which one. For selection and use, DGUV Rule 112-190 “Use of respiratory protective devices” is the key guideline in Germany.

Respiratory protective devices belong to category III of the PPE Regulation (EU) 2016/425 – protective equipment against fatal hazards or permanent damage to health. This entails particular duties: instruction with practical exercises, occupational health checks depending on the device and a structured maintenance programme. Extraction, closed systems or less hazardous substances take priority. Burdensome protective equipment must not be a permanent measure (Section 7(5) of the Hazardous Substances Ordinance, GefStoffV, Section 8(4) of the Biological Agents Ordinance, BioStoffV).

Filter devices and isolating devices

Filter devices clean the ambient air and depend on it. Isolating devices supply breathable air independently of the environment. How well a device protects is described by its protection level (Schutzniveau): it indicates up to which multiple of the limit value a device in good condition and with a proper fit protects adequately (DGUV Rule 112-190, section 3).

• Filtering facepiece FFP1 / FFP2 / FFP3

  Protection level4 / 10 / 30

  NotesAgainst dusts, fumes and liquid aerosols; FFP1 not against carcinogenic, mutagenic or reprotoxic (CMR) substances or risk group 2 and 3 biological agents

• Half or quarter mask with P3 or gas filter

  Protection level30

  NotesGas filters generally only against substances whose breakthrough can be smelt or tasted

• Full face mask with P3 or gas filter

  Protection level400

  NotesCovers the whole face; shorter duration of use than half masks

• Powered filter device with mask (class TM1 / TM2 / TM3)

  Protection level10 / 100 / 500

  NotesThe blower delivers the filtered air to the facepiece

• Powered filter device with hood or helmet (class TH1 / TH2 / TH3)

  Protection level5 / 20 / 100

  NotesLoose-fitting facepiece; no adequate protection if the blower fails

• Isolating devices: airline and self-contained breathing apparatus

  Protection leveldepending on design up to over 1,000

  NotesIndependent of ambient air; required where oxygen is lacking

Filter devices do not protect against oxygen deficiency: they must not be used below 17% oxygen by volume, and devices with CO filters not below 19%. In wastewater facilities and landfills, isolating devices are required below 19%, and separate rules apply in tanks and confined spaces.

How to choose the right device

1. 1

   Identify the hazard

   Which substances occur – as particles, gas or vapour –, in what concentration, and do they also act through the skin? What is the lowest oxygen content to be expected?

2. 2

   Determine the minimum protection level

   The protection level must be at least as high as the multiple of the limit value. Example: if the concentration is 20 times the occupational exposure limit (Arbeitsplatzgrenzwert), an FFP2 mask (10) is not sufficient – at least FFP3 or a half mask with a P3 filter (30) is needed.

3. 3

   Take biological agents into account

   Against airborne risk group 2 biological agents at least FFP2, against risk group 3 P3 filters or FFP3. P2 or FFP2 is only an option here in justified exceptional cases – with proven protective effect, documented in the risk assessment.

4. 4

   Consider ergonomics and the person

   Workload, climate, weight and the combination with other protective equipment affect the strain. Employees must be consulted before equipment is provided (Section 29 DGUV Regulation 1), and protective equipment must fit the individual (Section 2(2) of the PPE Use Ordinance, PSA-BV).

Fit test (Anpassungsüberprüfung) and seal

A tight-fitting mask only protects if it fits the face. Under DGUV Rule 112-190, tight-fitting facepieces – FFP masks, half and full face masks – may therefore only be provided after a successful fit test. It takes place before first use under the guidance of a person trained for this. Loose-fitting facepieces such as hoods and helmets do not need one.

• Qualitative: the person wears the mask in an atmosphere containing a taste or odour agent, such as saccharin solution or banana oil. If they perceive it, the mask does not fit. Suitable mainly for FFP, half and quarter masks.
• Quantitative: a measuring device compares the particle count outside and inside the mask. The target is a fit factor of at least 100 for FFP and half masks and 2,000 for full face masks. This method is preferable for CMR substances and acutely toxic substances.

Before every use, wearers check the seal themselves: close the filter connection with the palm, breathe in, hold the breath – the negative pressure must hold for about ten seconds. For FFP masks, the seal line is felt along after putting the mask on.

Duration of use and recovery time

Respiratory protection causes strain through breathing resistance, weight and microclimate. DGUV Rule 112-190 therefore gives guide values for the duration of continuous use, the subsequent recovery time and the duration of use per work shift. The former term “wearing time” (Tragezeit) is now called “duration of use” (Gebrauchsdauer).

• FFP mask without exhalation valve

  Duration of use75 min

  Recovery30 min

  Per shift360 min

• FFP mask with exhalation valve

  Duration of use150 min

  Recovery30 min

  Per shift420 min

• Half or quarter mask with P3 or gas filter

  Duration of use135 min

  Recovery30 min

  Per shift420 min

• Full face mask with P3 or gas filter

  Duration of use120 min

  Recovery30 min

  Per shift360 min

• Powered filter device up to 3 kg with hood or helmet

  Duration of useno limit

  Recovery–

  Per shift–

• Self-contained breathing apparatus over 5 kg

  Duration of use60 min

  Recovery30 min

  Per shift240 min

The values apply to work with a respiratory minute volume of 20 to 40 litres and to climatic conditions in line with the German workplace rules (ASR). For heavy work (over 40 to 60 litres) a factor of 0.7 is applied, for light work up to 20 litres a factor of 1.5. Example: FFP2 mask with valve during heavy work – 150 × 0.7 = 105 minutes at a time and 420 × 0.7 = 294 minutes per shift. Heat or additional protective clothing shorten the values further. The limits do not apply to emergencies such as rescue or escape.

Occupational health checks under AMR 14.2

The Occupational Health Care Ordinance (ArbMedVV) requires mandatory health check-ups for respiratory protective devices in groups 2 and 3 and offered check-ups for group 1 (Annex Part 4). Which devices belong to which group is set out in the occupational medicine rule AMR 14.2. It was revised on 22 June 2026 and is based on inhalation resistance and device weight:

• Group 1

  Health checkCheck-up to be offered (Angebotsvorsorge)

  ExamplesFilter devices with P3 particle filters, self-contained breathing apparatus under 5 kg, compressed airline breathing apparatus with mask

• Group 2

  Health checkMandatory check-up (Pflichtvorsorge)

  ExamplesFilter devices with gas or combined filters of all classes, fresh air hose breathing apparatus without blower

• Group 3

  Health checkMandatory check-up (Pflichtvorsorge)

  ExamplesSelf-contained compressed air and rebreather apparatus over 5 kg

• No group

  Health checkNo mandatory or offered check-up; allow a check-up on request if a risk cannot be ruled out

  ExamplesDevices with an inhalation resistance below 1 mbar (powered or hose-supplied devices with hood) or up to 5 mbar (P1 and P2 filter devices, FFP1 to FFP3 according to the manufacturer, powered filter devices with full or half mask), escape devices up to 5 kg

A mandatory check-up must have taken place before someone starts the activity (Section 4(2) ArbMedVV). The first check-up takes place within three months before the activity starts; further intervals follow AMR 2.1, and the health check certificate states the next date. You inform employees about the option of a check-up on request (Wunschvorsorge), for example during safety instruction. A fitness examination is something different: it only comes into question if the risk assessment shows it is needed – for example for group 2 or 3 devices combined with particularly strenuous work.

Instruction, exercises and maintenance

Before first use and at least once a year thereafter, you give instruction based on the operating instructions – with a theoretical part and practical exercises (Section 3(1) PSA-BV in conjunction with Section 31 DGUV Regulation 1, DGUV Rule 112-190 section 7). DGUV Principle 312-190 describes content and scope for each type of device. You draw up separate operating instructions (Betriebsanweisung) for the use of respiratory protective devices; if the risk assessment shows that marking is needed, the area is marked with the mandatory sign M017 “Wear respiratory protection”.

• Define a maintenance programme: cleaning and disinfection, inspection, replacement with original parts only, storage, disposal and documentation
• Clean, disinfect and check masks after every use; check stored masks every six months (mobile, e.g. on vehicles) or every two years (stationary)
• Check the expiry date of filters before use and withdraw parts past their storage life even if unused
• Use particle filters against biological agents only once and for no longer than one work shift
• Maintenance by a qualified person, such as a trained respiratory equipment maintenance technician (Atemschutzgerätewart)
• Only use self-contained breathing apparatus filled to at least 90% of the nominal pressure and have gas cylinders inspected periodically under the Ordinance on Industrial Safety and Health (BetrSichV)

Under DGUV Rule 112-190, persons under 18 may only use respiratory protective devices where this serves the purpose of their training – under competent supervision, with limit values complied with and sufficient oxygen, and not for rescue tasks.

Checklist: respiratory protection in the company

• Technical and organisational measures checked before respiratory protection and justified in the risk assessment
• Device selected according to oxygen content, pollutant and minimum protection level
• Employees consulted before provision, masks assigned personally
• Fit test carried out and documented before first use
• Duration of use and recovery time defined and described in the operating instructions
• Health checks arranged or offered under AMR 14.2, check-up on request communicated
• Instruction with practical exercises given before first use and at least once a year
• Maintenance programme, inspection intervals and filter expiry dates stored in the inspection register
• Rules of use such as seal checks and clean-shaven seal lines monitored by managers

Free templates for this guide

As PDF and Excel, free – to use in your own company.

• Safety instruction

  PPE issue record template (PDF) and issue list (Excel)

  PDF + ExcelFree download
• Testing duties

  Respiratory protection record template (PDF & Excel): device register and wearers

  PDF + ExcelFree download

Frequently asked questions