Breathing Air Quality Testing: Protecting Employees from Hidden Risks

When it comes to workplace safety, some risks are easy to spot — noise, machinery, or manual handling. But one of the most dangerous hazards is invisible: the air your employees breathe. Whether it’s from compressors, air-fed helmets, or supplied-air systems, the quality of breathing air can mean the difference between a safe shift and a serious health incident.

At DevineAir, we understand the importance of ensuring every workplace’s air quality meets the highest safety standards. That’s why we specialise in breathing air quality testing, helping businesses across the UK protect their people and maintain compliance.

Let’s look at why breathing air quality testing matters, what’s required by law, and the simple steps you can take to protect your team from hidden risks.

Why breathing air quality testing matters

If your business provides compressed or supplied air for breathing, such as air-fed helmets, airline respirators, or escape sets, you’re legally responsible for ensuring that the air is safe. Contaminated air can cause a range of short- and long-term health issues, from dizziness and headaches to organ damage and even fatalities in severe cases.

The Health and Safety Executive (HSE) makes it clear: employers must ensure that any respiratory protective equipment (RPE) supplied to employees provides breathable quality. (HSE guidance on RPE) sets out these duties under the Control of Substances Hazardous to Health (COSHH) Regulations and other relevant legislation.

Beyond protecting people, this testing protects your business. Poor-quality air can lead to downtime, failed inspections, or prosecution — all of which cost far more than regular testing and maintenance.

The standards you need to know

The main standard governing breathing air quality in the UK is BS EN 12021:2014. This sets strict limits on contaminants such as:

• Carbon monoxide (CO)
• Carbon dioxide (CO₂)
• Oil mist and vapour
• Water (moisture)
• Odour

Meeting this standard isn’t optional. It’s how you prove compliance and safeguard your workforce. The HSE’s HSG53 guide, Respiratory Protective Equipment at Work, also reinforces that all supplied-air systems must be tested and maintained to deliver air of breathing quality. (Read HSE’s HSG53 guidance here).

What’s actually tested and why it matters

A professional breathing air test looks at the exact composition of the air your employees inhale through your system. It checks for:

• Oxygen: Ensures there’s enough for safe breathing (typically 19.5–23.5%).
• Carbon monoxide (CO): Even low levels can be life-threatening.
• Carbon dioxide (CO₂): Causes headaches, fatigue, and poor concentration.
• Oil vapour and mist: Can enter air streams from poorly filtered compressors.
• Water content: Excess moisture encourages bacterial growth and rust.
• Odour: A strong indicator of contamination.

These contaminants are often invisible and odourless. Without testing, you simply wouldn’t know there’s a problem until it’s too late.

How often should you test?

The HSE doesn’t set an exact frequency, but industry best practice and our own recommendation at DevineAir is every three months for fixed systems and every time a mobile compressor is moved or serviced.

If your operations involve high-risk activities, such as confined space work or emergency response, you may need to test more frequently. Regular testing keeps you ahead of issues and provides a documented trail of compliance should the HSE visit your site.

Your compliance checklist: what employers should do

1. Identify all breathing air sources.
   Include compressors, cascade fills, and any air-fed or supplied-air equipment.
   
2. Nominate a responsible person.
   Appoint someone trained and competent to manage breathing air safety.
   
3. Book accredited testing.
   Use a professional testing company (like DevineAir) to analyse samples to BS EN 12021 standards and issue a certificate.
   
4. Keep up with maintenance.
   Regularly replace filters, check intake positions, and maintain dryers to avoid oil and moisture build-up.
   
5. Train employees.
   Workers should know what clean air should feel and smell like, and what to do if something seems off.
   
6. Record everything.
   Keep certificates, maintenance logs, and training records. If the HSE visits, this paperwork demonstrates that you’ve taken your responsibilities seriously.
   
7. Have a contingency plan.
   If a test fails, stop using that air source immediately, isolate it, investigate, and switch to a verified alternative until the issue is fixed.

Common issues we find during testing

Through years of field experience, our consultants often uncover the same recurring issues:

• Dedicated breathing air filters are not installed
• Out-of-date filters or dryers that have exceeded their lifespan.
• Moisture traps are not regularly drained, leading to excess water and bacteria.
• Compressor intakes positioned near vehicle exhausts, pulling in CO.
• Untrained staff unaware of what poor-quality air smells or feels like.

The good news? These problems are preventable with proactive testing and maintenance. Once identified, we work with your team to correct them quickly and cost-effectively.

Documentation and traceability 

Your breathing air quality certificate is proof that your system complies with BS EN 12021. It should include:

• The date and location of testing
• Detailed contaminant measurements
• Pass/fail results
• Any corrective actions required

Keep these certificates for inspection. The HSE or insurers may ask to see them during audits or after an incident. Good recordkeeping doesn’t just show compliance, but also shows a strong safety culture.

What happens if a test fails?

If your air fails to meet the required standard, take immediate action:

1. Stop using the air source for breathing purposes.
2. Investigate the cause — typically an intake issue, oil carry-over, or filter failure.
3. Rectify the fault — service the compressor, replace filters, or relocate intakes.
4. Re-test before resuming use.

Why breathing air testing makes business sense

Regular breathing air quality testing isn’t just about ticking boxes — it’s about preventing the kind of incidents that damage reputations and cause unnecessary downtime.

For employers, it brings:

• Peace of mind: Knowing your staff are safe and your systems are compliant.
• Operational reliability: Fewer unexpected stoppages due to air system failures.
• Legal protection: Demonstrable proof of compliance with HSE standards.
• Employee trust: Workers see that you take their health seriously.

These aren’t abstract benefits. They directly impact morale, productivity, and your bottom line.

How DevineAir can help

At DevineAir, we understand the importance of maintaining safe, clean air in every workplace. Our experts carry out breathing air quality testing to BS EN 12021:2014, giving you accurate results, practical advice, and full compliance peace of mind.

We also offer a range of environmental and safety services, including LEV testing, air quality assessments, noise and vibration monitoring, cleanroom validation, and lux level assessments. All these services are designed to keep your people safe and your business compliant.

Protect your team. Stay compliant. Breathe easier. Contact us today!