A powered air-purifying respirator (PAPR) uses a battery-powered fan to pull air through filters and deliver it to a hood, helmet or mask. It takes more setting up and upkeep than a P2 mask, so the real question is when it earns its place. This guide uses Safe Work Australia's silica guidance, WorkSafe Victoria and the makers' own listings, with the PAPR kits we supply as the examples. It is general information. Your risk assessment decides which respirator you need.
What is a PAPR and how does it work?
A PAPR has four main parts: a fan unit worn on a belt or backpack, filters (particle, gas or combination), a breathing tube and a headtop. The fan draws air through the filters and delivers it to the wearer, so you are not breathing the air through the filter yourself. The headtop can be a loose-fitting hood or helmet, or a tight-fitting half or full face mask. Sundström describes the over-pressure inside the headtop as keeping surrounding pollutants out.
When is a PAPR better than a P2 or P3 mask?
- When the face seal is the problem. WorkSafe Victoria says that where facial hair interferes with the fit of a respirator, a PAPR that does not rely on a facial seal, such as one with a loose-fitting helmet, needs to be used.
- When the work is long, hot or hard. Sundström says fan-assisted airflow can help during long periods of hard work in warm conditions.
- When the exposure is high. Safe Work Australia's 2024 guidance on working with crystalline silica substances (such as engineered stone) includes a table that matches respiratory protective equipment to the protection factor required, and it lists PAPRs with P3 filters among the options for the higher levels. Its construction guidance describes a P2 half-face respirator as generally the minimum for silica.
- When you want head, eye and respiratory protection in one. The 3M Versaflo TR300+ kit with the M-307 helmet lists AS/NZS 1716:2012 for respiratory protection, AS/NZS 1337.1:2010 for high impact eye protection and AS/NZS 1801:1997 Type 1 for the helmet (the previous edition; AS/NZS 1801:2024 is now current).
Mines have their own state legislation, so check what your site requires as well.
What can't a PAPR do?
- It only filters the air around you. It does not supply oxygen, so it is not for oxygen-deficient spaces or for contaminants that are unknown or immediately dangerous. Those jobs need supplied air or breathing apparatus.
- It has to match the hazard. Particle filters do not stop gases and vapours. The Sundström SR700 listing says it is for particles only and must not be fitted with gas filters.
- It depends on its battery and filters. Most units have battery, filter or airflow alarms. Follow the maker's schedule for charging, filter changes, cleaning and storage, and keep a spare battery for long shifts.
- It needs training. Wearers should know how to check airflow, what the alarms mean and how to clean and store the unit.
Do PAPRs need fit testing?
It depends on the headtop. A tight-fitting PAPR mask, like other half and full face respirators, has to seal to the face. A loose-fitting hood or helmet delivers air by flow rather than by a seal, which is why WorkSafe Victoria points to them where facial hair stops a mask sealing. Check AS/NZS 1715:2009 and your safety adviser for the fit-testing rules that apply to the headtop you choose. Our guide to getting a proper respirator fit covers fit testing for other respirators.
Which PAPR should you choose?
Start with the hazard, then the environment, then the other PPE the headtop has to work with:
- The hazard. Particles only, or gases and vapours as well? Choose filters to match.
- The environment. An explosive atmosphere needs an intrinsically safe or explosion-proof unit with a certification that matches your site.
- The other PPE. Hard hat, cap lamp bracket, hearing protection or welding visor.
- Run time and weight. Compare the hours the maker lists with your shift length.
- Spares. Filters, pre-filters, batteries, hoses and chargers.
Examples from our range, using the manufacturer information on each listing:
| Kit | Headtop | What the listing says | Suits |
|---|---|---|---|
| 3M Versaflo TR300+ with M-307 and M-940 cap lamp bracket | Helmet with eye protection | P3 filter and pre-filter. AS/NZS 1716:2012, 1337.1:2010 and 1801:1997 Type 1. | Mine and industrial work that needs a cap lamp |
| 3M Versaflo TR300+ with M-407 | Type 1 helmet with flame-resistant Nomex neck and shoulder shroud | For work with sparks and hot particles. Battery 10 to 12 hours. | Grinding, foundry and hot work |
| 3M Versaflo TR-819A starter kit (intrinsically safe) | Sold separately | Listing states mining Ex ia I Ma, ATEX certification, and SIMTARS certification for Queensland coal mining operations. Filters and headtop not included. | Hazardous atmospheres, including coal mining, where your site's approvals allow it |
| Sundström SR500 EX fan unit | Sold separately | Explosion-proof fan unit; classification II G Ex ib IIA/IIB T3 Gb. | Explosive gas atmospheres, with a certification that matches your site |
| Sundström SR700 particle PAPR | Hood, face shield or full face mask | Particles only. 1.1 kg with battery and filters. IP67. More than 6 hours in normal mode, 4 hours in boost. | Dusty jobs such as demolition |
| Maxisafe CleanAIR UniMask and AerGO kit | Face shield | AS/NZS 1716:2012. Up to 10 hours on the standard battery, or 20 hours with the Heavy Duty battery. | Hazardous dust including silica; construction and mining |
| Maxisafe CleanAIR CA-40G tunnelling kit | Hard hat with visor | AS/NZS 1716:2012. Universal lamp bracket and reflective tape kit included. | Tunnelling and mining |
| TRIDENT HEXHALE complete PAPR system | One-piece helmet with face shield | AS/NZS 1716:2012, 1337.1:2010 and 1801:1997. Three airflow rates. Up to 15 hours with the HD battery. | Industrial and mining particulates |
What maintenance does a PAPR need?
- Charge batteries as the maker directs, and keep a spare for long shifts.
- Change filters and pre-filters on the maker's schedule, or as soon as the low-flow alarm sounds.
- Clean headtops, hoses and visors as the instructions say, and store the unit sealed between uses.
- Replace damaged hoses, seals and visors before the next shift.
We list filters, pre-filters, batteries, chargers, hoses and headtops for 3M Versaflo, Sundström, CleanAIR and TRIDENT systems in our respiratory protection range.
Shop PAPR Respirators, Filters and Spares
Sources: Safe Work Australia: Working with crystalline silica substances (July 2024); Safe Work Australia: Construction duties tool, Silica; WorkSafe Victoria: Construction, preventing exposure to crystalline silica dust; and the manufacturer information on each 1st Safety product listing. The Australian standards are AS/NZS 1716:2012 and AS/NZS 1715:2009. This guide summarises these sources in our own words. It is general information, not legal advice.
1st Safety is based in Auburn, NSW, and supplies AS/NZS-compliant PPE to trades, construction, and industrial businesses across Australia.
Frequently Asked Questions
What does PAPR stand for?
PAPR stands for powered air-purifying respirator. A battery-powered fan draws air through filters and delivers it to a hood, helmet or mask.
Is a PAPR better than a P2 mask?
It can be for some jobs. Safe Work Australia's construction guidance describes a P2 half-face respirator as generally the minimum for silica. A PAPR is listed among the options for higher protection factors in its crystalline silica guidance, does not need a face seal if it has a loose-fitting headtop, and can ease long, hot shifts. It also needs charging, filter changes and cleaning. Your risk assessment decides.
Do PAPRs need fit testing?
Tight-fitting PAPR masks have to seal to the face like other half and full face respirators. Loose-fitting hoods and helmets deliver air by flow rather than a seal. Check AS/NZS 1715:2009 and your safety adviser for the fit-testing rules that apply to the headtop you choose.
Can I wear a PAPR with a beard?
With a loose-fitting hood or helmet, that is the idea. WorkSafe Victoria says that where facial hair interferes with the fit of a respirator, a PAPR that does not rely on a facial seal, such as one with a loose-fitting helmet, needs to be used. A tight-fitting mask still has to seal against the skin.
Does a PAPR protect against silica dust?
With the right P3 filter and headtop, PAPRs are listed in Safe Work Australia's silica guidance among the options for higher protection factors. Choose equipment certified to AS/NZS 1716:2012 and follow your risk assessment.
How long does a PAPR battery last?
It depends on the unit and the settings. The listings state 10 to 12 hours for the 3M Versaflo TR300+ kit with the M-407 headtop, more than 6 hours in normal mode and 4 hours in boost for the Sundström SR700, up to 10 hours for the CleanAIR AerGO (or 20 hours with the Heavy Duty battery at its lowest airflow setting, with new filters and a full charge), and up to 15 hours with the HD battery for the TRIDENT HEXHALE.
Can I use a PAPR in an explosive atmosphere?
Only a unit certified for it. The 3M TR-819A lists mining Ex ia I Ma and the Sundström SR500 EX lists II G Ex ib IIA/IIB T3 Gb, which are different ratings for different places. Standard units are not certified for explosive atmospheres. Check the certification against your site's requirements.
Do you supply replacement filters, batteries and hoses?
Yes. We list filters, pre-filters, batteries, chargers, hoses and headtops for 3M Versaflo, Sundström, CleanAIR and TRIDENT PAPR systems in the respiratory protection range, or contact our team on 0457 545 175.