Respiratory Protective Equipment (RPE) can help protect workers from hazardous substances in the air, including dusts, fumes, mists, gases and vapours.

But not all respirators protect against the same hazards.

An FFP3 disposable mask, for example, can provide a high level of particle filtration, but that does not mean it protects against gases or vapours. Likewise, choosing a reusable respirator is only part of the job – it must be fitted with the correct filter for the hazard.

The starting point should always be:

HAZARD → EXPOSURE → RPE TYPE → PROTECTION LEVEL → FILTER → FIT → COMPATIBILITY

1. Start With the Hazard

Before choosing respiratory protection, establish exactly what the wearer needs protection from.

Airborne hazards can include:

Dust
Fine particles
Fibres
Mists
Fumes
Gases
Vapours
Biological aerosols

You also need to consider the concentration of the contaminant, duration of exposure and working environment.

Never choose a respirator simply because it looks more protective.

The RPE must be suitable for the specific hazard and exposure.

2. Disposable or Reusable Respirator?

This is one of the first decisions you will need to make.

Disposable Respirators

Disposable filtering facepiece respirators are commonly referred to as FFP masks.

They are lightweight, convenient and widely used for protection against particles where an appropriate FFP respirator has been selected.

The three familiar classifications are:

FFP1 – Lower level of particle protection

FFP2 – Medium level of particle protection

FFP3 – Higher level of particle protection

But do not simply choose FFP3 for every application. The correct protection should be determined by the hazard and risk assessment.

You can browse our range of Disposable Face Masks and FFP Respirators here.

Reusable Respirators

Reusable half masks and full-face respirators use replaceable filters or cartridges.

They can be a better option where respiratory protection is required regularly or where protection against particular gases, vapours or combinations of hazards is necessary.

The important point is:

The mask and filter work together.

A reusable respirator fitted with the wrong filter may not provide the protection required.

You can browse our range of Reusable Respirators here.

3. What Does EN 149 Mean?

EN 149 is the standard commonly associated with filtering half masks used to protect against particles.

This is where you will see classifications such as:

FFP1
FFP2
FFP3

You may also see additional markings on the respirator.

NR – Non-reusable

R – Reusable

D – Has passed the optional dolomite dust clogging test

Always check the full product specification rather than relying solely on the FFP number.

4. FFP1, FFP2 or FFP3?

One of the most common questions when buying disposable respiratory protection is:

“Which FFP rating do I need?”

There is no single answer for every workplace.

FFP1

FFP1 provides the lowest protection level of the three FFP classes and may be suitable for certain lower-risk particle applications where the required protection factor is achieved.

FFP2

FFP2 provides greater particle protection and is widely used across construction, manufacturing and other industrial environments where the risk assessment requires this level of protection.

FFP3

FFP3 provides the highest level of protection within the FFP classifications and is used where a higher level of particle protection is required.

The important word is particles.

FFP1, FFP2 and FFP3 do not mean protection against every airborne hazard.

If disposable particle protection is appropriate for the task, you can compare our FFP Disposable Face Masks here.

5. Valved or Unvalved Masks?

Disposable respirators are available with and without exhalation valves.

Valved Respirators

An exhalation valve can make breathing out easier and may help reduce heat and moisture build-up inside the mask.

This can improve comfort during longer periods of wear.

Unvalved Respirators

With an unvalved respirator, air is inhaled and exhaled through the filtering material.

These are often simpler and less expensive.

However, there are applications where controlling what the wearer exhales is also important. A conventional exhalation valve can allow exhaled air to leave without passing through the main filter material.

The choice should therefore be based on the application rather than comfort alone.

6. Reusable Half Masks

Reusable half masks cover the nose, mouth and chin and are designed to accept compatible replaceable filters.

They can be useful where workers regularly require respiratory protection and can provide protection against different hazards depending on the filters fitted.

Potential advantages include:

Reusable mask body
Replaceable filters
Different filter options
Comfortable face seals
Adjustable harnesses
Potentially lower long-term cost for frequent users

But selecting the correct filters is critical.

Browse our Reusable Respirators here.

7. Full-Face Respirators

A full-face respirator covers the eyes as well as the nose and mouth.

Depending on its specification and filters, this can provide respiratory protection together with additional face and eye coverage.

They can be useful where the identified hazard requires both.

However, full-face masks are more substantial pieces of PPE and need to be correctly selected, fitted, maintained and used.

8. Understanding A, B, E and K Filters

Reusable respirator filters can carry letters identifying the types of gases or vapours they are designed to protect against.

Common classifications include:

A – Certain organic gases and vapours

B – Certain inorganic gases and vapours

E – Sulphur dioxide and certain acidic gases and vapours

K – Ammonia and certain organic ammonia derivatives

You may therefore encounter filters described as:

A1
A2
ABEK1
ABEK2

These markings have specific meanings and capacities.

The important rule is simple:

Identify the contaminant first – then select the appropriate filter.

Never choose a filter simply because it has more letters printed on it.

You can browse our range of Respirator Filters here.

9. What Does P Mean?

The P marking relates to particle filtration on relevant reusable respirator filters.

You will commonly encounter:

P3 provides the highest particle-filter performance of these classes.

You may also see combination filters such as:

A2P3

ABEK2P3

These combine protection against specified gases or vapours with particle filtration.

Again, the combination must be suitable for the actual contaminant and concentration.

Our Respirator Filters range includes particle, gas and combination filter options.

10. EN 143 and EN 14387

Two other standards you will frequently encounter when buying reusable respiratory protection are:

EN 143 – Particle filters

EN 14387 – Gas filters and combined filters

These standards are different from EN 149, which you will commonly see on disposable filtering facepieces.

Understanding this distinction makes respiratory protection much easier to navigate.

11. The Mask and Filter Must Be Compatible

This is extremely important.

You cannot simply buy a reusable mask from one manufacturer and assume any filter will attach to it.

Respirators use specific filter connections and approved combinations.

Filters must be compatible with the particular respirator.

Always check the manufacturer’s compatibility information.

This becomes especially important when a workplace already has reusable masks and is purchasing replacement filters.

When buying replacement filters, use the Respirator Filters section to compare the available options, but always confirm compatibility with your existing mask.

12. Face Fit Is Critical

A tight-fitting respirator relies on achieving an effective seal against the wearer’s face.

If contaminated air can leak around the edges, it can bypass the filter.

This means a technically excellent respirator can provide inadequate protection if it does not fit the wearer correctly.

Where tight-fitting RPE is used, appropriate face-fit testing is an essential part of the selection process.

Different faces may also require different models or sizes.

One mask does not necessarily fit everyone.

13. Facial Hair Can Affect the Seal

Beards, stubble and other facial hair in the sealing area can prevent a tight-fitting respirator from achieving an adequate seal.

This is not solved by simply tightening the straps.

Where a tight-fitting facepiece cannot achieve the required seal, a different form of respiratory protection may need to be considered.

This is one of the most important practical issues when introducing RPE into a workplace.

14. Fit Check vs Face-Fit Test

These two terms should not be confused.

Face-Fit Test

A formal procedure used to establish whether a particular make, model and size of tight-fitting respirator is capable of fitting the individual wearer adequately.

Pre-Use Fit Check

A check performed by the wearer whenever the respirator is put on to help confirm it has been positioned and sealed correctly.

You need both where applicable.

A previous face-fit test does not mean the wearer can put the mask on incorrectly and still be protected.

15. Think About Other PPE

Respiratory protection may need to be worn alongside:

Safety helmets
Safety glasses
Goggles
Face shields
Ear defenders
Protective clothing

One item can interfere with another.

For example, safety glasses may interfere with the seal of some respirators, while respirators can cause eyewear to mist.

Straps from helmets and other equipment can also affect fit and comfort.

Choose PPE as a complete system.

16. Comfort Matters

Respiratory protection may need to be worn for considerable periods.

Consider:

Breathing resistance
Weight
Face seal comfort
Strap adjustment
Heat build-up
Moisture
Field of vision
Compatibility with eyewear
Compatibility with helmets
Communication requirements

A respirator that is uncomfortable is more likely to be adjusted, loosened or removed.

17. How Long Do Filters Last?

There is no universal answer.

Filter life depends on factors including:

Filter type
Contaminant
Concentration
Humidity
Temperature
Breathing rate
Duration of use
Storage

Gas and vapour filters should be managed using an appropriate filter change schedule based on the manufacturer’s information and workplace assessment.

Do not rely on smell or taste as the primary indication that a filter needs changing.

18. Storage Matters Too

Reusable masks and filters should be stored correctly between uses.

Poor storage can expose equipment to:

Dust
Contamination
Moisture
Chemicals
Sunlight
Physical damage

Filters may also have specific storage requirements once opened.

Follow the manufacturer’s instructions.

19. Inspect Reusable Respirators

Reusable RPE needs maintenance.

Check components such as:

Face seal
Straps
Buckles
Valves
Filter connections
Filters
Visors
Inhalation valves
Exhalation valves

Damaged or deteriorated components can compromise protection.

Cleaning, inspection, maintenance and replacement should form part of the workplace RPE programme.

20. Don’t Forget Training

Workers need to understand:

Why RPE is required
What hazard they are being protected against
Which respirator to use
Which filter to use
How to put it on correctly
How to perform a pre-use fit check
When filters need changing
How to clean it
How to store it
When equipment needs replacing

Buying the right respirator is only part of providing effective respiratory protection.

Respiratory Protection Ordering Checklist

What is the contaminant?
Is it a particle, gas, vapour or combination?
What is the concentration?
How long is the exposure?
What protection factor is required?
Disposable or reusable RPE?
FFP1, FFP2 or FFP3?
Is a gas or vapour filter required?
Which filter classification is appropriate?
Is particle filtration also required?
Is the filter compatible with the mask?
Has the wearer been face-fit tested where required?
Could facial hair interfere with the seal?
Will the RPE work with other PPE?
How will reusable equipment be cleaned?
How will filters be managed and changed?
Have employees been trained?

Ready to Choose Your Respiratory Protection?

Don’t start with:

“What’s the strongest mask you’ve got?”

Start with:

HAZARD → EXPOSURE → RPE TYPE → PROTECTION → FILTER → FIT → COMPATIBILITY

Respiratory protection is one area of PPE where guessing is not good enough.

The correct respirator must be suitable for the contaminant, provide the required level of protection, fit the individual wearer and be compatible with the other PPE being used.

When you are ready to order, browse our Disposable Face Masks, Reusable Respirators or Respirator Filters to compare the options available.

And, as with other PPE, RPE should not automatically be the first control measure. Exposure should first be prevented or adequately controlled by other reasonably practicable measures, with suitable respiratory protection used where it remains necessary.

Written by Steve Cree at 21/08/2026