How to Select the Right Respirator for Your Work
Updated: 25 September 2026
Choosing respiratory protective equipment (RPE) starts with the hazard, not the mask. Dust from cutting or sanding, welding fume, machining mist, solvent vapour and gases behave differently, and the right respirator depends on what is in the air, how much is present, the work being performed and the person wearing it.
A respirator also needs to work with your other PPE, provide an adequate level of protection and, for tight-fitting models, fit the individual wearer correctly.
Quick answer
Identify the airborne contaminant and exposure first, apply practical controls such as extraction where appropriate, select RPE and filters suitable for the hazard and required protection level, fit-test tight-fitting respirators, fit-check them every time they are worn, and maintain and replace filters according to the manufacturer's instructions and your workplace respiratory protection program.
Important respiratory protection guidance
RPE should not automatically be the first or only control for airborne contaminants. Elimination, substitution, isolation, local exhaust ventilation and other practical controls may be required. Air-purifying respirators must not be used where oxygen may be deficient, where contaminant concentrations are unknown, or in atmospheres immediately dangerous to life or health. These situations require specialist assessment and respiratory protection selection.
1. Identify what is in the air
The first step is identifying the airborne contaminant generated or used during the task. The Safety Data Sheet (SDS), process information, workplace risk assessment and, where required, air monitoring can all form part of this process.
| Hazard type |
Workshop examples |
Respirator consideration |
| Dusts and fibres |
Cutting, sanding, grinding, drilling, crushing and handling powders |
Particulate filtration. The required filter class and respirator type depend on the contaminant and exposure. |
| Fumes |
Welding, brazing, soldering and other hot processes |
P2 or P3 particulate filtration may be required for thermally generated particles, subject to the task and exposure assessment. |
| Mists and aerosols |
Metalworking fluids, spraying and atomised liquids |
Selection depends on the substance and how the mist is generated. Check the SDS and applicable guidance. |
| Gases and vapours |
Solvents, paints, chemicals, ammonia and acid gases |
Requires a gas or vapour filter matched to the particular contaminant. A particulate filter alone does not protect against gases or vapours. |
| Combined hazards |
Spraying, some welding and chemical processes |
A combined particulate and gas/vapour filter may be required. |
| Low oxygen or unknown atmosphere |
Confined spaces, emergency situations or unknown contaminant levels |
Do not rely on an air-purifying respirator. Specialist supplied-air respiratory protection and competent assessment may be required. |
A task name by itself is not enough to select RPE. Two workshops carrying out apparently similar work may have different materials, ventilation, exposure levels, process times and other controls.
2. Choose the appropriate type of respirator
Respirators broadly fall into air-purifying and supplied-air systems.
Disposable particulate respirators
Disposable respirators are lightweight, single-use air-purifying respirators designed for particulate hazards when the selected respirator provides the required protection for the task.
A disposable respirator is still a tight-fitting respirator. It needs to suit the individual wearer, achieve an effective seal and be fit-tested where required.
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Reusable half-face respirators
Reusable half-face respirators seal around the nose, mouth and chin and accept replaceable filters or cartridges. Depending on the filter fitted, they may be configured for particulates, particular gases or vapours, or a combination of hazards.
They do not provide eye protection, and the filters must be matched to the contaminant. Tight-fitting reusable masks also require individual fit-testing.
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Full-face respirators
A full-face respirator can provide respiratory protection together with coverage of the eyes and face. Depending on the respirator and filter configuration, it can also provide a higher protection factor than a half-face respirator.
The correct filter is still essential and tight-fitting full-face respirators require fit-testing.
Powered air-purifying respirators (PAPR)
A PAPR uses a battery-powered blower to draw air through filters and deliver filtered air to the wearer. Depending on the system, this may be through a tight-fitting facepiece, helmet, hood or other headtop.
PAPR can be useful where work is physically demanding or RPE needs to be worn for longer periods, but the correct system, filters, airflow, battery condition and headtop still need to suit the hazard and task.
A loose-fitting PAPR headtop and a tight-fitting PAPR facepiece have different fit requirements, so always follow the manufacturer's instructions and the workplace respiratory protection program.
Browse powered air-purifying respirators
Supplied-air respirators
Supplied-air respirators receive breathing air from an independent source rather than filtering the surrounding air. They are used in applications where an air-purifying respirator is not suitable or cannot provide the required protection.
Selection, breathing-air quality, equipment configuration and maintenance are specialist matters. General-purpose compressed air should not simply be assumed to be suitable breathing air.
3. Match the filter to the contaminant
P1, P2 and P3 particulate filters
Under the current Australian/New Zealand respiratory protection system, particulate filters are marked P1, P2 or P3. The filter classification is only one part of the selection. The respirator configuration and facial fit also determine the protection actually achieved.
| Filter |
General classification |
Important point |
| P1 |
Mechanically generated particulates |
Not suitable for particulates generated by hot processes such as welding or soldering. |
| P2 |
Mechanically and thermally generated particulates |
Commonly considered for dust and fume hazards where the required protection level is appropriate. |
| P3 |
Highest particulate filter classification in the current P1/P2/P3 system |
P3 filter performance does not automatically mean the complete respirator provides P3-level wearer protection. The respirator configuration matters. |
P2 does not mean "protects against everything". A P2 particulate respirator protects against suitable particle hazards. It does not by itself protect against solvent vapours, gases or every workplace atmosphere.
Gas and vapour filters
Gas and vapour filters are selected according to the particular gas or vapour they are designed to absorb. The filter letter identifies the contaminant group, while the filter class relates to absorption capacity.
| Filter type |
Typical contaminant group |
Current colour identification |
| A |
Certain organic vapours |
Brown |
| B |
Certain acid and inorganic gases |
Grey |
| E |
Sulphur dioxide and certain other acid gases |
Yellow |
| K |
Ammonia and certain ammonia derivatives |
Green |
| AX and specialist types |
Specific low-boiling organic compounds and other specialist contaminants |
Check the specific filter marking and manufacturer's instructions |
No single gas or vapour filter protects against every chemical. Where both particles and gases or vapours are present, a suitable combination filter may be required.
For example, a filter marked A1P2 combines an organic vapour filter classification with particulate filtration. That does not mean it is suitable for every organic vapour or every exposure level. Always check the SDS, contaminant, concentration, respirator compatibility and manufacturer's selection information.
View the Maxisafe respirator filter selection chart
4. Make sure the respirator provides enough protection
Knowing the contaminant is only part of the job. The respirator also needs to provide an adequate level of protection for the concentration present in the workplace.
Australian respiratory protection guidance uses protection factors to match RPE to the relationship between airborne contaminant concentration and the applicable workplace exposure standard or limit.
Do not guess the protection factor. If contaminant concentration is not known, or the exposure is complex, air monitoring or advice from a competent occupational hygiene or WHS professional may be required before RPE can be properly selected.
Other factors can also change what RPE is practical:
- how long the respirator will be worn
- the physical intensity of the task
- heat and humidity
- whether eye or face protection is also required
- communication and visibility requirements
- whether glasses, welding helmets or other PPE interfere with the respirator seal
- the individual wearer's face shape, medical considerations and ability to use the selected RPE.
5. Fit-test the respirator, then fit-check it every time
A tight-fitting respirator only works as intended when it seals correctly against the individual wearer's face.
WorkSafe Queensland recommends fit-testing:
- before a tight-fitting respirator is selected or used for the first time
- at least once each year
- whenever facial characteristics change in a way that could affect the seal.
A fit-check is different. It is the quick seal check the wearer carries out every time the respirator is put on. A fit-check does not replace fit-testing.
Facial hair and tight-fitting respirators
Beards, moustaches, sideburns or stubble between the respirator sealing surface and the skin can prevent a tight-fitting respirator from sealing correctly. Workers using tight-fitting RPE need the sealing area to be clean shaven. Where that is not possible, another appropriately selected respiratory protection system may need to be considered.
Does a PAPR remove the need for fit-testing?
Not automatically. Some PAPRs use tight-fitting facepieces and some use loose-fitting hoods or headtops. The fit requirements depend on the actual system. Check the manufacturer's instructions and your respiratory protection program.
6. Inspect, maintain and replace filters correctly
Disposable respirators
Disposable respirators are intended for single use. Follow the manufacturer's instructions for use and disposal.
Reusable respirators
Reusable RPE should be inspected regularly. Check the facepiece, straps, valves, seals, filter connections and other components for damage, contamination or wear, and clean and maintain the respirator according to the manufacturer.
When should particulate filters be changed?
WorkSafe Queensland recommends replacing a particulate filter when breathing through it becomes difficult or when the filter becomes visibly dirty or damaged. Manufacturer instructions may specify additional requirements.
When should gas and vapour filters be changed?
Gas and vapour cartridges have a finite absorption capacity. Their service life can be affected by contaminant type and concentration, breathing rate, workload, temperature, humidity and filter class.
A workplace using gas and vapour filters should establish an appropriate filter replacement schedule rather than simply waiting until obvious breakthrough occurs. Store filters as directed by the manufacturer. Gas and vapour cartridges may continue absorbing contaminants from surrounding air while they are not being worn.
Workplace Exposure Limits change on 1 December 2026
WES to WEL transition
Australia is transitioning from Workplace Exposure Standards (WES) to Workplace Exposure Limits (WEL) for airborne contaminants from 1 December 2026.
Some individual limits and advisory notations are changing. Workplaces that use or generate dusts, fumes, gases, vapours or mists should review the contaminants relevant to their processes and consider whether their exposure assessment, controls, monitoring and RPE arrangements need to be reviewed.
Changing exposure limits does not simply mean choosing a "stronger mask". Respiratory protection sits within the wider process of identifying the hazard, assessing exposure and applying suitable controls.
Australian respiratory protection standards are also changing
AS/NZS 1715:2009 and AS/NZS 1716:2012 remain important references during the current transition, but Standards Australia is progressively moving Australia and New Zealand to a new suite of ISO-based respiratory protection standards.
The transition is expected to replace the two existing standards by 2030. This means product classifications, terminology and selection methods will progressively evolve. Always check current regulator guidance, applicable standards and the manufacturer's documentation rather than relying only on older product descriptions or colour coding.
Respirator selection checklist
- Identify the contaminant: dust, fume, mist, gas, vapour or combination.
- Review the SDS and process: understand what is being used or generated.
- Control the hazard first: consider extraction, isolation, substitution and other practical controls.
- Understand the exposure: determine the required level of respiratory protection.
- Choose the RPE type: disposable, reusable, full-face, PAPR or supplied-air as appropriate.
- Select the correct filter: particulate, gas/vapour or combination.
- Check compatibility: make sure other PPE does not compromise the respirator.
- Fit-test: confirm a tight-fitting respirator fits the individual wearer.
- Fit-check: check the seal every time the respirator is worn.
- Maintain and replace: inspect, clean, store and change filters according to the respiratory protection program and manufacturer's instructions.
Common respirator questions
Does a P2 respirator protect against solvent vapours?
No. P2 is a particulate filtration classification. Gas and vapour hazards require an appropriate gas/vapour filter or another respiratory protection system selected for the contaminant.
Is P3 always better than P2?
P3 is the higher particulate filter classification, but the overall protection achieved depends on the complete respirator configuration and fit. The correct choice is the one that provides adequate protection for the actual hazard and exposure.
How often should a respirator be fit-tested?
For tight-fitting RPE, WorkSafe Queensland recommends fit-testing before initial selection or use, at least annually and whenever facial characteristics change in a way that may affect the seal.
Can I wear a tight-fitting respirator with a beard?
Facial hair or stubble between the sealing surface and the skin can prevent a reliable seal. Another appropriately selected respiratory protection system may need to be considered where the sealing area cannot be kept clean shaven.
How do I know when to change a gas or vapour cartridge?
Gas and vapour cartridges should be managed using an appropriate replacement schedule based on the contaminant, concentration, filter capacity, work conditions and manufacturer's instructions.
Sources and further guidance
- WorkSafe Queensland: Respiratory protective equipment (RPE)
- Safe Work Australia: Workplace Exposure Limits for airborne contaminants
- Standards Australia: Respiratory Protection Standards transition information
- Maxisafe: Respirator and filter selection information
This article provides general product-selection information only. It does not replace a workplace risk assessment, exposure monitoring, Safety Data Sheets, applicable legislation or standards, manufacturer instructions, or advice from a competent WHS or occupational hygiene professional.
Need help narrowing down your respiratory protection options?
Tell the AusTech team what process you are carrying out, the contaminant or SDS if available, how long the RPE will be worn and what other PPE is being used. We can help you identify relevant respirator, filter and PAPR product ranges and manufacturer resources.
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