How to Build a Respiratory Protection Program (RPP) in Australia: The Complete Framework (2026)

Published: March 2026 | By Anitech Occupational Hygiene Team

Part of our Mask Fit Testing Australia: Complete Guide →

Most Australian businesses that issue respirators to workers have a procedure. Far fewer have what the Australian Standard actually requires: a respiratory health effects of DPM Protection Program (RPP).

An RPP is not a single document. It is a documented, managed system — covering hazard assessment, respirator selection, fit testing, training, maintenance, records, and review — that ensures workers are genuinely protected by their respirators, not just issued equipment and left to their own devices. Under AS/NZS 1715:2009 (Selection, use and maintenance of respiratory protective equipment), every workplace where respirators are used must have an RPP in place.

This guide explains exactly what an RPP must contain, how to build one, and how to keep it compliant as your workplace evolves.

Why an RPP Matters: More Than a Procedure Document

Many employers assume that issuing the right respirator and training staff to wear it is sufficient. AS/NZS 1715 takes a more demanding view: each element of respiratory protection must be managed systematically, documented, and reviewed, because the failure of any single element can expose workers to hazards even when they believe they are protected.

For workplaces with diesel-powered equipment, understanding workplace exposure standard for DPM is an essential part of WHS compliance.

Consider these common RPP failures:
– A worker is issued a half-face respirator but is never fit tested → the respirator may leak on their face
– A fit test is done but records are not kept → the employer has no evidence of compliance when an inspector visits or a compensation claim arises
– Workers are not trained in the correct donning sequence → they wear the respirator incorrectly, invalidating the seal
– Respirator filters are not replaced on schedule → the protection level degrades without the worker knowing
– The RPP is written once and never reviewed → it uses an obsolete standard or doesn’t reflect a change in the workplace’s hazard profile

An RPP prevents all of these failures by treating respiratory protection as a managed system rather than a transaction (issue → forget).

The 8 Core Elements of a Compliant RPP

AS/NZS 1715 identifies eight elements that a Respiratory Protection Program must address. Each is explained below with practical implementation guidance.

Element 1: Respiratory Hazard Assessment

The RPP begins with understanding what hazards your workers are exposed to, and at what level.

A hazard assessment must identify:
– The specific airborne contaminants present (particulates, gases, vapours, biological agents)
– The concentration of each contaminant in the breathing zone of workers (measured or estimated)
– The relevant workplace exposure standards (WES) — the Safe Work Australia WES document sets these for substances including silica (0.05 mg/m³), diesel particulate matter (DPM), isocyanates, welding fumes, and hundreds more
– Whether concentrations can be reduced to below the WES through engineering or administrative controls
– Where engineering controls cannot achieve compliance, the residual exposure level that respirators must address

Practical tip: Hazard assessment requires air monitoring — not just assumption or reference to a safety data sheet. An occupational hygienist can conduct personal and area air monitoring to establish actual worker exposure levels, which feeds directly into the correct respirator selection in Element 2.

If you have an existing assessment, check whether it is current. AS/NZS 1715 requires reassessment when:
– A new substance is introduced
– Process or DPM control measures change
– Monitoring results indicate exposure levels have changed
– An incident occurs that suggests the current controls are inadequate

Element 2: Respirator Selection

Based on the hazard assessment, employers must select respirators with an assigned protection factor (APF) sufficient to reduce the worker’s exposure to safe levels.

Key selection criteria under AS/NZS 1715 include:

Respirator Type	Typical APF	Fit Test Required?
Disposable P2/N95 filtering facepiece	10	Yes (tight-fitting)
Half-face elastomeric with P2 filter	10	Yes (tight-fitting)
Half-face elastomeric with combined P2/gas filter	10	Yes (tight-fitting)
Full-face respirator with P3 filter	20–1000	Yes — quantitative only
Loose-fitting PAPR with hood	25–1000	No
Supplied air respirator (demand mode)	10	Yes (tight-fitting)
Supplied air respirator (pressure demand)	1000+	Yes (tight-fitting)

Key principle: Never select a respirator with an APF lower than required by the exposure assessment. If a worker’s silica exposure is 10× the WES (0.5 mg/m³ vs 0.05 mg/m³), they need a respirator with an APF ≥10 — a P2 disposable just qualifies, but only if it actually seals against their face, which requires fit testing.

The RPP must document the selection decision — specifically, why the chosen respirator type is appropriate for the hazard level.

Element 3: Fit Testing Program

The fit testing component of your RPP must specify:

Who must be fit tested (all workers using tight-fitting respirators)
Which respirator models are tested (make, model, and size)
What method is used (qualitative or quantitative — see Qualitative vs Quantitative Fit Testing →)
Who conducts the tests (a competent person; RESP-FIT accredited tester strongly recommended)
When tests are conducted (before first use; annually; on trigger events)
Trigger events that require unscheduled retesting (weight change, dental work, facial surgery, new respirator model, etc.)
Records — what is captured and how long records are kept (minimum 30 years as health monitoring records)

The RPP should also specify what happens if a worker fails a fit test — which includes testing alternative models, considering PAPR alternatives, and reviewing whether engineering controls can be enhanced. Your RPP should also define the specific triggers that require out-of-cycle retesting before the next scheduled annual test — our detailed guide on how often respirator fit testing is required under Australian standards covers every retesting trigger under AS/NZS 1715.

Full guide: Mask fit testing — the complete process →

Element 4: Medical Evaluation

Some workers may have medical conditions that affect their ability to safely wear a respirator. Conditions to consider include:

Cardiovascular disease: The work of breathing against resistance (particularly with half- or full-face respirators) increases cardiac workload
Respiratory conditions (COPD, severe asthma): Increased breathing resistance can worsen symptoms
Claustrophobia: Some workers cannot tolerate the feeling of a tight-fitting respirator
Skin conditions: Eczema or psoriasis in the facial sealing area can affect both fit and worker comfort
Dental or facial structure issues: These may prevent adequate fit with conventional tight-fitting respirators

The RPP should specify a medical evaluation process — typically a questionnaire reviewed by an occupational physician or occupational health nurse — for workers before they are issued a tight-fitting respirator.

This does not need to be a full medical examination for every worker. A structured questionnaire identifying relevant risk factors, with physician review for flagged responses, is typically sufficient.

Element 5: Respirator Training

Under AS/NZS 1715, workers must be trained in the selection, use, limitation, and maintenance of their specific respirators. Training must be conducted before first use and refreshed whenever the respirator model changes, annually as part of the RPP review, or whenever a worker demonstrates incorrect use.

Training must cover:

Why the specific respirator is required for their role (motivation — not just rule-following)
How to correctly don the respirator (donning sequence, adjustment points)
How to conduct a positive and negative pressure fit check after donning
Limitations of the respirator (what it protects against, what it does not)
How to recognise signs of respirator failure or inadequate seal
How to doff safely (contamination risk during removal)
Maintenance, cleaning, storage, and inspection procedures
When to replace cartridges/filters or the entire unit
Who to report to if they experience discomfort, suspected exposure, or respirator failure

Practical tip: Training records must be kept. These should record the worker’s name, the date, what was covered, and the name of the trainer.

Element 6: Maintenance, Inspection, and Storage

Respirators must be maintained in a serviceable condition to provide the rated protection. Your RPP must include:

Inspection schedule: Workers should inspect their respirator before each use. Check for cracked or deteriorated facepiece, damaged or missing straps, worn head harness, contaminated inhalation or exhalation valves.

Filter and cartridge replacement schedule: For particulate filters, replace when breathing resistance increases noticeably or after known heavy exposure. For chemical cartridges, replacement must follow a change-out schedule based on contaminant concentration, exposure time, humidity, and temperature — not just appearance or smell. (A cartridge that is saturated may give no warning before breakthrough.)

Cleaning procedure: Elastomeric half-face and full-face respirators must be cleaned regularly (frequency depends on use intensity). Disposable respirators are single-use.

Storage requirements: Store respirators away from heat, sunlight, and contaminants. Elastomeric respirators should not be stored compressed or deformed. Do not store respirators in toolboxes or open areas where contamination can occur.

The RPP must specify who is responsible for maintenance activities and how it is documented.

Element 7: Record Keeping

The RPP’s record-keeping element must specify:

Fit test records: Worker name, employer, respirator make/model/size, test date, method, result, tester name and RESP-FIT accreditation number — kept for 30 years
Medical evaluation records: Worker name, date, outcome — retained as health records
Training records: Worker name, date, content covered, trainer — retained for the duration of employment plus 5 years minimum (30 years if the worker was exposed to hazardous substances)
Respirator inspection and maintenance records: For reusable respirators, inspection dates, condition noted, and replacement of components
RPP review records: Date of annual review, findings, changes made

Note: Under the model WHS Regulations, records related to health monitoring (including fit testing) must be kept for 30 years, even if the worker leaves the organisation. This is because the latency of occupational respiratory diseases (silicosis, mesothelioma, occupational asthma) can extend for decades.

Full record-keeping requirements guide →

Element 8: Program Review and Improvement

An RPP is a living document, not a set-and-forget procedure. AS/NZS 1715 requires the RPP to be reviewed and updated:

Annually as a minimum
When a new hazard or substance is introduced to the workplace
When monitoring results indicate exposure levels have changed
After any incident involving respiratory exposure or suspected equipment failure
When the standard is updated (as AS/NZS 1715 was by AS/NZS ISO 16975-3:2023)
When new respirator models are introduced (requiring new fit tests)

The review should assess whether each element of the RPP is effective — not just whether the procedures exist on paper.

RPP Documentation: What to Include

A compliant RPP document should include the following sections:

Scope and purpose: What workplaces and roles does the RPP cover?
Hazard identification: List of respiratory hazards, with current monitoring data and WES
Respirator selection criteria: Which respirator type is required for which task and why
Fit testing schedule and procedure: Including methods, who tests, records, and trigger events
Medical evaluation process: Questionnaire, referral pathway, recording
Training requirements: Content, schedule, records
Maintenance, inspection, and storage procedures: By respirator type
Record keeping requirements: What is kept, where, how long
Roles and responsibilities: Who is responsible for each element
Review schedule: Who reviews, when, and what triggers an unscheduled review

Download our RPP framework template: Use the WHS Manager Fit Testing and RPP Compliance Checklist → as a starting point.

Common RPP Failures and How to Avoid Them

Based on occupational hygiene audits, the most common failures in existing RPP programs are:

1. No hazard quantification. Many programs list “silica dust” as a hazard without any air monitoring to establish actual concentrations. Without measured data, respirator APF selection is guesswork.

2. Fit testing records that expire. Annual retesting is scheduled but not tracked — workers miss their annual retest and continue using a respirator that hasn’t been validated for another year.

3. No trigger event policy. Workers are not aware that weight changes or dental work require them to be retested. The RPP must communicate this.

4. Filter change-out schedules based on appearance, not chemistry. Gas-phase contaminants (organic vapours, isocyanates) break through activated carbon cartridges without smell or colour change. A change-out schedule based on cartridge life calculation is required.

5. Training treated as a one-time event. Workers forget donning procedures, develop workarounds, or start wearing the respirator incorrectly. Annual retraining and direct observation during use should be part of the RPP.

Who Should Develop and Manage Your RPP?

An RPP can be developed in-house if the relevant competency exists. However, the hazard assessment (particularly air monitoring) and the fit testing component are best conducted by a qualified occupational hygienist — particularly one who holds RESP-FIT accreditation for the fit testing component.

An occupational hygienist can:
– Conduct personal air monitoring to quantify worker exposure
– Select the correct respirator class for each hazard scenario
– Conduct RESP-FIT accredited quantitative fit testing for your workforce
– Develop the written RPP documentation to AS/NZS 1715 requirements
– Train workers in the use and maintenance of their specific respirators
– Conduct annual RPP reviews and update documentation

Anitech’s team of occupational hygienists provides the complete RPP service — from initial hazard assessment through to fit testing, documentation, and annual review. Contact us for an obligation-free scoping discussion.

Frequently Asked Questions

Is an RPP legally required in Australia?
Yes. AS/NZS 1715:2009 requires any workplace that uses respirators to have a respiratory protection program in place. This standard is referenced in WHS legislation and codes of practice across all Australian jurisdictions.

How long does it take to develop an RPP?
A basic RPP for a single site with limited hazards can be developed in 1–2 days of professional time plus field work (air monitoring). A complex multi-hazard or multi-site RPP may take several weeks. Anitech can provide a scoping assessment to estimate timeframe and cost.

Does a small business need an RPP?
Yes, if workers use tight-fitting respirators. The RPP for a small business may be simpler in scope, but the core requirements — hazard assessment, correct respirator selection, fit testing, training, and records — still apply.

Can we use a generic RPP template?
A template is a starting point, not a finished RPP. An RPP must be site-specific: it must reference the actual hazards in your workplace, the specific respirator models you use, and the actual workers who need to be fit tested. Generic templates that are not customised to your workplace do not satisfy the AS/NZS 1715 requirement.

How often must the RPP be reviewed?
At minimum annually. Also whenever a significant change occurs — new hazard, new substance, new process, new monitoring data, new respirator model, or after any respiratory exposure incident.

Anitech’s occupational hygienists develop compliant Respiratory Protection Programs for Australian businesses across all industries and risk profiles. Contact us for a scoping discussion or to arrange air monitoring, fit testing, and RPP development for your workplace.