Types of Respirators for Industrial Use: Key Features and Top Picks

In industrial environments, respiratory hazards are a serious concern. The International Labour Organization (ILO) reports that more than one billion workers are exposed to harmful airborne substances like dust, fumes, vapors, and pollutants every year. Without proper protection, these hazards can lead to long-term health problems and even fatal diseases.

To combat these risks, industries rely on various types of respirators designed to protect workers from inhaling dangerous particles and chemicals. In this article, we'll explore the most common respirators used in industrial settings and discuss their key features to help you choose the right one.

Key Takeaways

• Respirators provide more protection than standard masks by filtering harmful particles, while masks are mainly for basic barrier protection.
• Different types of respirators include disposable, reusable, and powered options, each designed for specific workplace hazards.
• A proper respirator fit test ensures the respirator seals tightly on the face and prevents harmful particles from bypassing the filter.
• Reusable options, like the full face respirator, require regular cleaning and maintenance to work effectively.
• NIOSH-approved respirators meet the safety standards required for industrial use.

Masks vs. Respirators: What’s the Difference?

Masks and respirators may look similar, but they serve very different purposes. Masks are typically used for general protection, like preventing the spread of droplets in everyday settings. They don't form a tight seal on the face and aren't designed to filter out fine particles or dangerous chemicals.

Respirators, on the other hand, are designed to protect workers from hazardous airborne particles and gasses. They create a tight seal around the face and use filters to block harmful substances. Unlike masks, respirators must pass safety standards, such as those set by NIOSH, and often require a respirator fit test to ensure proper protection.

Types of Respirators

The different types of respirators are tailored to specific needs and offer different levels of protection based on the work environment and exposure duration. Respirators can be disposable, reusable, or powered. Some models, like the powered air purifying respirator, are equipped with advanced filtration systems to ease breathing in high-risk areas.

The National Institute for Occupational Safety and Health (NIOSH) classifies particulate-filtering respirators based on their ability to remove or filter particulate matter in the air. The filter capacity of a respirator mask is set at at least 95%, 99%, and 99.97% of airborne particles. Respiratory equipment is further classified into three designations (N, R, and P), which are based on the material of the mask’s resistance to oil.

Here's an introduction to the main types of respirators and their key features.

Filtering Facepiece Respirator Mask (FFR)

A Filtering Facepiece Respirator (FFR) is a type of disposable respirator mask that covers the nose and mouth and is designed to filter out airborne particles. FFRs are lightweight and made from non-woven fabric. They typically have two straps that secure the mask to the face, creating a tight seal around the nose and mouth. FFRs are single-use masks, meaning they should be disposed of after a single shift or when they become damaged or contaminated. 

FFRs are ideal for environments where workers are exposed to dust, pollen, smoke, and other non-oil-based particulates. They are commonly used in healthcare settings, construction sites, and other industries where airborne particle filtration is necessary. Due to their disposable nature, they are best suited for tasks that do not require prolonged use or where sanitation and infection control are critical.

Our Top Pick

Moldex 4700 N100 AirWave Series

The Moldex 4700 N100 AirWave Series is a high-performance disposable respirator designed to provide superior protection against airborne particulates. It features an exclusive wave design that increases the surface area for better breathability and comfort. The full foam face seal reduces pressure on the face, making it more comfortable for extended wear. The Dura-Mesh® shell resists collapsing in heat and humidity, allowing for longer, more reliable use.

Key Features:

• NIOSH-certified to filter at least 99.97% of non-oil-based particulates.
• FlexFit® design moves with your face for added comfort during long wear.
• Metal-free molded nose bridge seals without a noseband for easier use.

Elastomeric Half Mask Respirator (EHMR)

An Elastomeric Half Mask Respirator (EHMR) is a reusable respirator mask that covers the nose and mouth and has replaceable filter cartridges. These respirators are made of durable materials such as silicone or rubber and provide a higher level of protection compared to disposable masks.

They feature a flexible, form-fitting facepiece that creates a secure seal around the nose and mouth. EHMRs also have adjustable straps and exhalation valves designed to ensure comfort and prevent heat buildup from inside the mask. The filter cartridges featured in EHMRs are replaceable, allowing for extended use of the respirator.

EHMRs are ideal for industries where workers are exposed to gasses, vapors, and airborne particulates that require a higher level of filtration. They are commonly used in industrial settings such as manufacturing, chemical processing, and emergency response. Due to their reusable nature, EHMRs are cost-effective for long-term use and can provide consistent protection in environments with frequent or prolonged exposure to hazardous substances.

Our Top Pick

Miller Half Mask Respirator Kit LPR-100

The Miller Half Mask Respirator Kit LPR-100 provides excellent respiratory protection with its low-profile design, making it ideal for professionals who require both safety and comfort. It fits under most welding helmets, including the Weld-Mask™ 2, and provides up to 99.97% filtration against airborne particulates, both oil-based and non-oil-based. The compact size improves visibility and ensures compatibility with other personal protective equipment.

Key Features:

• P100 filters offer 99.97% filtration efficiency with a wrap-around spark guard for extra protection and durability.
• Minimal dead air space limits re-breathing exhaled air, increasing user comfort.
• Four-point head strap adjustment with a comfort cushion for a customized fit.

Elastomeric Full Facepiece Respirator Mask

Similar to the EHMR, an Elastomeric Full Facepiece Respirator is a reusable respirator that covers the entire face, including the eyes, nose, and mouth. It also has replaceable filter cartridges and provides comprehensive protection against airborne particles, gases, and vapors. 

This type of respirator features a clear face shield that offers protection for the eyes in addition to respiratory protection. The full face respirator design ensures a secure seal and minimizes the risk of exposure to hazardous substances. Elastomeric Full Facepiece Respirators are ideal for environments where there is a risk of exposure to harmful particles, gasses, and vapors that can affect both the respiratory system and the eyes. 

Our Top Pick

Sundstrom SR 200 Full Face Mask Glass

The SR 200 Full Face Mask Glass is a reliable full face respirator designed for demanding industrial environments. With a full-face design, it provides excellent respiratory and eye protection against hazardous substances, making it suitable for use with various filters and cartridges. The mask’s silicone facepiece provides a comfortable, secure fit, while its tempered glass lens offers durability and a wide field of vision.

Key Features:

• NIOSH-certified and compatible with a range of filters and cartridges, as well as PAPR and supplied air systems.
• Low breathing resistance with three inhalation valves and two exhalation valves for improved comfort.
• Scratch-resistant polycarbonate visor provides a large field of vision and excellent eye protection.

Powered Air Purifying Respirator (PAPR)

A Powered Air Purifying Respirator (PAPR) is a type of respirator mask that uses a battery-powered blower to draw air through filters and supply purified air to the user. PAPRs can be configured with either a tight-fitting facepiece or a loose-fitting hood or helmet.

PAPRs consist of a motorized blower unit, a battery pack, filter cartridges, and a headpiece. The blower unit forces air through the filters, providing a continuous flow of clean air to the user. This positive airflow helps reduce breathing resistance and increases comfort, making PAPRs suitable for long-term use.

PAPRs are best suited for situations where high levels of respiratory protection and comfort are needed, such as healthcare settings, pharmaceutical manufacturing, and hazardous waste handling. They are particularly useful in environments with high concentrations of airborne contaminants or where users need to wear respiratory protection for extended periods.

Our Top Pick

MIRA Safety MB-90 Powered Air Purifying Respirator 

The MIRA Safety MB-90 Powered Air Purifying Respirator is a versatile and durable powered air purifying respirator (PAPR), ideal for hazardous environments requiring advanced respiratory protection. It offers continuous airflow of 90 liters per minute, providing comfort and reducing breathing resistance. Compatible with all 40mm NATO standard threaded gas masks, it supports easy interchangeability of filters.

Key Features:

• Runs on standard AA batteries, delivering up to 12 hours of operation.
• Positive pressure system for added protection by keeping contaminants out.
• Belt-mounted unit improves mobility and comfort during long use.

Supplied-Air Respiratory Equipment (SAR)

Supplied-Air Respiratory Equipment (SAR), also known as Airline Respirators, are respirators that provide clean air from a stationary source through a hose. The air is supplied from a compressor or a cylinder and delivered to the user's facepiece. SARs consist of a facepiece, a hose, and an air supply source. The facepiece can be a half mask, full face respirator mask, or a hood/helmet, depending on the level of protection required.

SARs are ideal for environments where the air is heavily contaminated, and the concentration of hazardous substances is too high for air-purifying respirators. They are commonly used in confined spaces, chemical plants, painting operations, and other areas where reliable, uncontaminated air supply is critical. SARs are also used in situations where long-duration respiratory protection is needed without the bulk and weight of carrying filter cartridges.

Our Top Pick

3M™ Scott™ Ska-Pak Plus Supplied-Air Respirator

The 3M™ Scott™ Ska-Pak Plus Supplied-Air Respirator is a versatile supplied-air respiratory system designed for emergency and industrial applications. It provides a continuous supply of clean air in hazardous environments, including confined spaces and areas classified as immediately dangerous to life or health (IDLH). With a full face respirator and an integrated escape cylinder, the Ska-Pak Plus offers a secure and comfortable fit for extended use.

Key Features:

• Combination Type C positive pressure respirator with escape cylinder for emergency use in IDLH conditions.
• E-Z Klip cylinder retention system allows for fast and easy cylinder changes.
• Available with a padded Kevlar® or nylon harness, or an integrated full-body harness for fall protection.

Self-Contained Breathing Apparatus (SCBA)

A Self-contained Breathing Apparatus (SCBA) is a type of respirator that provides the user with a portable supply of breathable air from a compressed air cylinder. This type of industrial respiratory equipment consists of a facepiece connected to an air cylinder, a pressure regulator, and a harness that allows the user to carry the cylinder on their back. The facepiece creates a secure seal around the user's face, and the air supply is delivered through the regulator. SCBAs provide a limited supply of air, typically lasting between 30 minutes to an hour, depending on the cylinder's capacity and the user's breathing rate.

SCBAs are ideal for use in highly hazardous environments, such as firefighting, rescue operations, and chemical spill responses. They are also essential for entering confined spaces with potentially toxic atmospheres. SCBAs provide the highest level of respiratory protection and are used in situations where the air quality cannot be guaranteed.

Our Top Pick

MSA G1 Industrial SCBA

The MSA G1 Industrial SCBA is a highly durable self-contained breathing apparatus (SCBA) designed for industrial settings requiring reliable respiratory protection. This SCBA system provides a 30-minute supply of breathable air from a low-pressure cylinder, making it ideal for emergency response and hazardous environments. With a lightweight, ergonomic harness, the system distributes weight evenly to reduce fatigue during extended use. The G1 IRC also offers compatibility with other MSA SCBA systems, enhancing its versatility across various industries.

Key Features:

• Wide field of view with cross-contamination prevention in the G1 facepiece for improved visibility and safety.
• Shoulder straps coated with Nanosphere for resistance against water and chemicals, enhancing durability.
• Removable soft goods for easy cleaning and maintenance, improving ease of use in tough environments.

NIOSH-Approved Particulate Filtering Respirators

NIOSH-approved particulate filtering respirators are designed to remove harmful particles from the air workers breathe. These types of respirators are classified based on their filtration efficiency and resistance to oil. The three main categories—N, R, and P—determine how resistant the filters are to oil-based particles, which is crucial for selecting the right respirator mask for specific work environments.

Here's an overview of the classifications:

Respirator Fit Testing Guide

Aside from choosing the right type of respiratory protection, proper respirator fit is also important to ensure its effectiveness. A respirator fit test refers to the process of verifying the fit of the respirator to the user’s face. This test provides critical adjustments needed to seal and protect from contaminants. 

There are two primary methods for a respirator fit test: Qualitative Fit Test (QLFT) and Quantitative Fit Test (QNFT).

Qualitative Fit Test (QLFT)

A Qualitative Fit Test (QLFT) is a pass/fail test that relies on the user’s sensory response to detect the presence of a test agent. QLFT is typically used for half-mask respirators, including filtering facepiece respirators and elastomeric half masks. The QLFT process involves the following steps:

1. Selection of Test Agent: Common test agents include saccharin (sweet taste), Bitrex (bitter taste), isoamyl acetate (banana smell), and irritant smoke. These agents are chosen because they trigger a distinct sensory response, making it easier to detect if the respirator fit is poor.
2. Preparation: The user first puts on the selected respirator mask, which can be a disposable or reusable type. A hood is placed over the user’s head to trap the test agent inside.
3. Sensitivity Test: Before the fit test, a sensitivity test is performed to verify that the user can detect the test agent at low concentrations. This ensures that the test will be effective, as the user needs to sense the agent to determine fit.
4. Fit Test: The selected agent is introduced into the fit test hood while the user performs exercises such as talking, turning their head, or bending. These movements simulate real working conditions and help verify that the respirator mask maintains a proper seal throughout.
5. Pass/Fail Result: If the user does not detect the test agent, the respirator fit test is passed, indicating a proper seal. If the user detects the test agent, adjustments or a different respirator may be needed.

Quantitative Fit Test (QNFT)

A Quantitative Fit Test (QNFT) uses precise instruments to measure the amount of leakage into the respirator mask and provides a numerical fit factor. QNFT can be used for any tight-fitting respirator and offers a more objective assessment of fit. The quantitative fit test process involves:

1. Selection of Testing Device: Common devices include the PortaCount, Controlled Negative Pressure (CNP) REDON, and Ambient Aerosol Condensation Nuclei Counter (CNC). These devices measure leakage and calculate an accurate fit factor.
2. Preparation: The respirator user dons the respirator, and a probe is attached to the respirator or a sample line is fitted to the mask. This allows the testing device to measure the concentration of particles both inside and outside the mask.
3. Baseline Measurement: The testing device first measures the ambient particle concentration outside the respirator to establish a baseline. This helps determine how well the mask can prevent these particles from entering during use.
4. Fit Test: The user performs exercises, similar to those in a respirator fit test like QLFT, while the device measures the number of particles inside the respirator. This verifies that the respirator maintains its seal during real-world activities.
5. Fit Factor Calculation: The fit testing device calculates a fit factor by comparing the particle concentration inside the respirator to the ambient concentration outside. A higher fit factor indicates a better fit.
6. Pass/Fail Result: The respirator fit test is passed if the fit factor meets or exceeds the minimum acceptable level specified for the respirator type. If the fit factor is below the acceptable level, adjustments or a different respirator may be needed.

Respirator Maintenance

Proper maintenance can keep your respirator in working order in hazardous environments. This applies to all types of respirators, including a full face respirator, welding respirator, and powered air purifying respirator. Regular cleaning, inspection, and storage extend the equipment's lifespan and ensure it remains effective.

Follow these steps for optimal care:

• Cleaning: After each use, clean the respirator mask with warm water and mild detergent, removing filters or cartridges first. This prevents dirt, oils, or other contaminants from affecting the seal or performance.
• Inspection: Before and after use, inspect the respirator for any signs of damage like cracks, tears, or faulty valves. For reusable types, check the exhalation and inhalation valves and replace any damaged parts.
• Filter and Cartridge Replacement: Filters and cartridges need replacing based on manufacturer guidelines or if they become clogged. This is especially important for welding respirators and PAPRs, which may be exposed to more harmful particles.
• Respirator Fit Test: Over time, normal wear can affect the fit of your mask. Conducting regular respirator fit tests helps verify that the mask still forms a proper seal and provides full protection.
• Storage: Store your respirator in a clean, dry location away from direct sunlight and extreme temperatures. Use a storage bag to protect it from dust and debris, keeping it in good condition for the next use.

Regular maintenance, fit testing, and choosing the right respirator are key to ensuring effective protection in hazardous environments. Taking care of your equipment helps maintain its performance and ensures a proper seal when it’s needed most. With the right practices, you can stay safe and extend the life of your respirator.

FAQs

Is an N95 a respirator?

Yes, an N95 is a type of respirator mask. It filters at least 95% of airborne particles and is not resistant to oil. NIOSH certifies N95 respirators for use in workplaces with airborne hazards.

What is the most common respirator?

The most common respirator is the N95 respirator, widely used in healthcare, construction, and industrial settings. It provides reliable protection against non-oil-based airborne particles.

What is an OSHA respirator?

An OSHA respirator refers to any respirator that meets the safety standards set by the Occupational Safety and Health Administration (OSHA). These standards ensure that respirator masks provide adequate protection against workplace hazards.

Is a dust mask considered a respirator?

Yes, some dust masks are considered respirators if they are NIOSH-approved, such as N95 masks. However, simple cloth or surgical masks are not classified as respirators.

What are the three types of filter series for respirators?

The three types of filter series for respirators are N, R, and P. N-series filters are not resistant to oil, R-series are somewhat resistant, and P-series filters are strongly resistant to oil.

What is a Level 3 respirator mask?

A Level 3 respirator mask typically refers to masks used in medical or surgical settings, offering a high level of fluid resistance and filtration, though it may not be NIOSH-approved like an N95 respirator.

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