Problem with my respirator?

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I am fairly new to welding and have a couple of questions. currently i am going to school for my level C welding certificate, iv been in the program for about a month now, and i have a half face mask respirator with p100 filters, but when im doing SMAW, i can smell the flux through my mask. I have the mask half way up my nose, its cuping my chin and i shave regularly, i do the preassure tests, so im confidant its not the seal thats the problem, would it be my filters? i know i havn't been storing them correctly, i've just been throwing them in my locker, would that make them expire that fast?Side note, the joint past my knuckles on every finger is sore, it has been for about three days, would that be from breathing in the flux through my respirator? i heard flux might have some effects like that on my body, like chills and sore joints.
Reply:Heavy metals...... Long ago we never were concerned about them. Lots of my old working buddies are dead now. Hmmmmmm.I'd start out by reading the MSDS for the materials you are working with.I'd make sure my welding station had very good ventilation.Try and keep your head out of the plume of smoke.Change the respirator cartridges. Moisture will break them down. Store in a dry, vented area.You will be able to smell the smoke with conventional filters. You would need a fresh air fed mask to eliminate the odors.It's good that you are becoming informed on your health issues as a welder.Lincoln SA200's... at least 15 - 20. They come and go. Growing partial to the "Short Hoods" in my old age. Last count on Short Hoods was 13 in possession.
Reply:You have a leak somewhere.  If everything is working right and it is well fitted you should smell nothing using P100 filters doing normal stick welding on basically clean metal.Check the exhale valve and valve seat to make sure it is working and clean of debris.  Check your filters for holes.  As filters load up with particles, they actually get better at filtering, not worse - unless you get a hole in them from a spark or other damage.  Check gasket areas where parts seal together - anything between the clean zone inside and the dirty zone outside can be the cause.  And then there is face fit - you think you have a good seal, but are you sure?Anything damaged, either replace the parts (if you can find parts) or get new (mask and or filters).Moisture does not generally affect P100 particle filters, but it will affect activated carbon chemical cartridges.  There is a lot of confusion between the 2 types of filters/cartridges among users, so this is not uncommon.  Welding is mainly a particle hazard, so you need filters, not carbon cartridges.  There are always specialty exceptions, of course...HTH-DaveXMT304 with: 22A Feeder, or HF251 Hi Freq DC TIG air cooled
Reply:As others have said you respirator is leaking probably because it dosen't fit you.  Where I work we are required to be fit tested by qualified people.  They fit a respirator to you then use a really bad smelling smoke to test the fit.  Respirators also come in diffenent quality levels and target gasses or solids.  Good brands are 3M and North but I am sure there are others.  The ones from the local hardware store are probably not what you want to be using.  There is not a one size fits all or one respirator covers all hazards.  Dan D.