PPE

Respirator Guide: P1, P2 and P3 Filters, Fit Testing and AS/NZS 1716

Choose the right respirator for dust, fumes and chemicals. Covers filter classes, fit testing, standards and respirator types for Australian workplaces.

By the Star Safety Supplies team 10 min read

Two reusable half face respirators with filter cartridges, two white disposable masks and a pack of spare filters on a steel workshop bench

Key points

  • Respiratory protection is the last control used when hazards cannot be removed or controlled enough by higher order controls.
  • P1, P2 and P3 are particulate filter classes, and gas or vapour hazards need a gas filter matched to the substance.
  • A tight fitting respirator must be fit tested to the wearer and needs a clean shaven seal, and a fit check is done every time it is put on.
  • Respirators listed against AS/NZS 1716 are selected, used and maintained with AS/NZS 1715 as the guide.

This guide helps supervisors, safety officers and tradespeople choose the right respirator for dust, fumes and chemicals in Australian workplaces. It explains filter classes, fit testing and the differences between disposable, half face, full face and powered respirators.

Respiratory protection sits at the bottom of the hierarchy of controls. It is used with higher controls such as ventilation, wet cutting and dust extraction when those controls do not reduce the airborne hazard enough on their own.

When is a respirator needed?

A respirator is needed when airborne dust, fumes, mist, gas or vapour remain after higher order controls have been applied. The business must identify the hazard and select the right protection for the specific contaminant and the work being done. Check the safety data sheet (SDS) of the substances used to understand the form and toxicity of the airborne hazard. For silica and asbestos work follow the specific regulator guidance and codes of practice that apply in your state or territory. Ask what tasks generate the contaminant, how long workers are exposed and whether the work area is confined or ventilated. Write down the hazard and the required protection before you start looking at products.

The business provides the respirator, makes sure it is suitable and fits the worker and provides training on its use. Workers must use the respirator as instructed. A respirator is not a substitute for removing the hazard or controlling it at the source. Keep a register of the respirators issued, the fit test records and the filter change schedule. Review the register when the task changes or a new substance is introduced.

What do P1, P2 and P3 mean?

P1, P2 and P3 are the three particulate filter classes under AS/NZS 1716. They describe the type of particles the filter is designed to capture. The class must match the contaminant and a higher class is not a reason to skip fit testing.

Filter class Made for Notes
P1 Mechanically generated particles such as dust from sanding or cutting Not for fumes or smoke
P2 Mechanically and thermally generated particles such as dust and metal fumes The class most often listed for site dust
P3 All particles including highly toxic materials Full P3 protection only in a full face respirator

When you read a product listing check that the filter class is stated clearly. Match the class to the hazard you identified from the SDS and the regulator guidance. If the work creates metal fumes or smoke as well as dust, a P1 filter is not enough. Remember that the filter class only works when the respirator seals to the face.

Which standards apply to respirators?

AS/NZS 1716 sets performance requirements for respiratory protective devices. AS/NZS 1715 gives guidance on selection, use and maintenance of respiratory protective equipment. Look for products listed against AS/NZS 1716. Some imported products are listed against EN standards so check the listing on the product page to confirm which standard applies. If a product page does not show the standard, ask the supplier before you buy.

Both standards work together. AS/NZS 1716 covers the device performance and AS/NZS 1715 covers the program around it. Use AS/NZS 1715 to build your respiratory protection program including selection, fit testing, training, maintenance and record keeping.

What is the difference between disposable, half face and full face respirators?

Disposable masks are single use and cover the nose and mouth. Reusable half face respirators use replaceable filters and cover the nose, mouth and chin. Full face respirators also cover the eyes and are the only way to get full P3 protection. The JSP Force Typhoon 8 Half Mask Respirator Asbestos/Silica/Dust Kit With P2 Filters is an example of a reusable half face kit. The North Full Face Mask Black Medium is an example of a full face piece.

Choose the type based on the hazard, the required filter class and the wearer's comfort for the shift length. Disposable masks suit short tasks and are thrown away after use. Half face respirators suit daily use where filters are changed regularly. Full face respirators suit work where the eyes also need covering or where P3 protection is specified. Check the product listing for the filter connection type so you order the correct spare filters.

When are powered air purifying respirators used?

A powered air purifying respirator (PAPR) uses a battery powered blower to push filtered air into a hood, helmet or mask. Some PAPRs use a loose fitting hood or helmet so check the listing for the headtop type. PAPRs are useful for long shifts and where a tight seal is hard to achieve. Check the listing for the filter class and the headtop type to match the hazard. The Maxisafe CA-1 Short Hood & Basic PAPR Kit RSH1133A is an example of a PAPR kit.

Consider a PAPR when workers have facial hair that cannot be removed, when the work is strenuous and breathing resistance is a concern or when the task runs for several hours. Check the battery run time on the listing and plan for charging or spare batteries. Make sure the headtop covers the eyes if the hazard requires eye protection. Train workers on how to start the unit, check the airflow and store the kit after use.

How do gas and vapour filters differ?

Particulate filters do not stop gases or vapours. Gas filters carry letters and numbers that show the type of contaminant and the capacity class. Combined filters cover both particulates and gases in one cartridge. Match the filter to the substances on the SDS and the manufacturer's selection chart. The North A1B1E1 Filter Pair is an example of a combined gas filter.

Read the SDS to find the chemical name and the form of the hazard. Use the manufacturer's selection guide to pick the correct filter code and capacity. If the work involves both dust and vapour a combined filter simplifies the kit. Keep a record of the filter code, the date fitted and the task it is used for. Replace gas filters on the schedule the manufacturer recommends even if breathing resistance feels normal.

Why does fit testing matter?

A tight fitting respirator only protects if it seals to the face. Fit testing by a competent person is required before first use, when the model changes, when the face changes and at least once a year. The qualitative method uses a test agent the wearer tastes or smells and is for half face respirators only. The quantitative method uses equipment to measure leakage and can be used for half and full face respirators. Both methods meet the requirements of AS/NZS 1715.

Arrange fit testing before the job starts so there is no delay on site. Use the same make, model and size the worker will wear on the job. Keep a record of the test date, the method used, the result and the respirator details. If a worker changes weight significantly, has dental work or grows facial hair schedule a new test. Do not assume a different size of the same model will fit without a new test.

How do you do a fit check before each use?

A fit check is done every time the respirator is put on. Follow the manufacturer's instructions for the positive or negative pressure check. Adjust the straps and redo the check if air leaks are felt. A fit check does not replace a formal fit test but it confirms the seal is adequate for that use.

Teach every wearer the fit check steps during their induction. Post a simple reminder near the respirator store. If a wearer cannot get a seal after adjusting the straps try a different size or model and record the change. A fit check is quick and it is the last chance to catch a leak before the worker enters the work area.

Does facial hair affect a respirator?

There must be no hair between the face and the seal of a tight fitting respirator. Stubble breaks the seal and reduces protection. Where facial hair cannot be removed a loose fitting powered option such as a PAPR hood may suit. Check with the supplier to confirm the headtop and filter combination for the hazard.

Include the clean shaven rule in your site PPE policy and the pre-start briefing. If a worker arrives with stubble offer a PAPR if one is available for the hazard or send the worker to shave before they enter the area. Do not rely on a fit check to overcome a beard leak. Document the policy so there is no ambiguity when a supervisor enforces it.

How do you look after and replace respirators?

Disposable masks are thrown away after use or when damaged, wet or hard to breathe through. Reusable masks are cleaned and stored as the manufacturer says. Replace filters as the manufacturer says or when breathing resistance increases. Gas filters have a limited service life based on the contaminant and concentration. Keep a record of filter changes and inspections.

Store spare filters in their original packaging in a clean dry area away from chemicals and sunlight. Write the date opened on the filter packet. Inspect reusable facepieces before each use for cracks, torn straps or missing valves. Clean the facepiece with the wipes or solution the manufacturer recommends and let it dry fully before storage. Follow the manufacturer's care instructions for each model.

How do you buy respirators for a team?

Create a short list of approved respirators by task. Keep the same model a worker was fit tested on. Stock spare filters for each model. Use the trade buying page for pathways to quick order by SKU and to request a quote for volume or project needs.

Standardise on one or two models per task to simplify fit testing and spare parts. Enter the approved SKUs into your ordering system so purchasers cannot accidentally buy a different model. Set a minimum stock level for each filter type so you never run out mid project. Use the quick order page to paste a list of SKUs and quantities when the store runs low.

Frequently asked questions

Is a P2 mask enough for silica dust?

Follow the silica guidance from the regulator in your jurisdiction. The right respiratory protective equipment depends on the exposure assessment. Fit and fit testing decide the protection achieved.

What is the difference between P2 and P3?

P2 filters capture mechanically and thermally generated particles. P3 filters capture all particles including highly toxic materials. Full P3 protection is only achieved when the filter is used in a full face respirator.

Do disposable P2 masks need fit testing?

Yes. When a disposable P2 mask is tight fitting it must be fit tested before first use and at least annually. A fit check is still done every time it is put on.

Can I wear a respirator with a beard?

A tight fitting respirator cannot seal over facial hair. Stubble or a beard breaks the seal. A loose fitting powered air purifying respirator with a hood may be an option where facial hair cannot be removed.

How often should respirator filters be changed?

There is no fixed interval. Change particulate filters when breathing resistance increases or they are damaged. Change gas filters based on the manufacturer's service life guidance for the specific contaminant and concentration. Follow the manufacturer instructions and the standard the product is listed against.

For help choosing respirators or filters, call 1300 078 277 or visit our contact page.

Shop respiratory protection

Sources

This guide is general information for Australian workplaces. It is not legal advice. Requirements differ between states and territories and change over time, so check the current guidance of your regulator and the standard itself before relying on it.

More safety guides

All safety guides