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Face Fit Testing

5 Proven Benefits of Face Fit Testing

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We provide sampling and consultancy services throughout the UK and Ireland


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What is Face Fit Testing? – Ensuring Respiratory Protection in the workplace

In today’s industrial and occupational settings, ensuring the safety and well-being of workers is of paramount importance. One of the critical aspects of workplace safety is respiratory protection, especially in environments where airborne contaminants pose a risk to workers’ health. Face fit testing is a crucial procedure employed to determine the effectiveness of respiratory protective equipment, such as masks and respirators, in creating an effective seal between the mask and the wearer’s face. This testing process plays a vital role in safeguarding workers from exposure to hazardous airborne particles and gases.

Understanding the Need for Face Fit Testing:

Exposure to harmful airborne particles, such as dust, fumes, smoke, and biological agents, can lead to serious respiratory diseases and health issues among workers. Respiratory protective equipment, like filtering facepiece respirators (FFRs) and half-face or full-face masks, forms the first line of defense against these hazards. However, for these devices to provide optimal protection, they must fit snugly and create an airtight seal against the wearer’s face. A poor-fitting mask can lead to leaks, allowing contaminated air to enter and compromising the effectiveness of the protective equipment.

This is where face fit testing comes into play. It ensures that the selected respirator or mask is suitable for the individual wearer’s facial features, ensuring a proper seal and adequate protection against airborne hazards.

The Testing Process:

The test involves a series of procedures to assess the compatibility between a specific respirator/mask and an individual’s face. There are two main methods of testing: quantitative fit testing and qualitative fit testing. Both methods involve the user wearing a Face fit Testing hood.

Quantitative Fit Testing: This method employs specialized equipment to numerically measure the leakage around the mask’s seal during different exercises or movements. These measurements provide a precise assessment of the respirator’s fit and its protective capabilities. Quantitative fit testing is considered more accurate and reliable, as it eliminates subjectivity and provides objective data.

Qualitative Fit Testing: In this method, the wearer dons the respirator and is exposed to a test agent, often a harmless or odoriferous substance like saccharin or Bitrex. The wearer performs a series of exercises, such as moving the head, talking, and breathing deeply. If the wearer detects the test agent’s taste or smell inside the mask, it indicates a poor fit and potential leakage. Qualitative fit testing is more subjective and relies on the wearer’s sensory perception.

Protective equipment (RPE) requires testing because it is only useful if it does not leak. One of the main reasons it does is because it does not fit the wearer’s face correctly. Because everybody’s face is different, it is unlikely that one type of RPE will suit everyone that wears it. Face fitting ensures that the RPE fits, and therefore doesn’t leak and consequently provides sufficient protection to the wearer.

5  Proven benefits of Face Fit Testing:

  1. Worker Safety: The primary purpose of testing is to ensure the safety of workers. By accurately assessing the compatibility of a respirator or mask with an individual’s face, the risk of exposure to harmful contaminants is significantly reduced.
  2. Compliance: Regulatory bodies and occupational health and safety standards mandate the use of proper respiratory protection in certain work environments. Testing ensures compliance with these regulations, protecting both workers and employers from potential legal and financial repercussions.
  3. Cost-Effectiveness: Testing contributes to cost savings by preventing the purchase and use of ineffective respirators or masks. Investing in proper testing eliminates the need for trial and error and ensures that the selected equipment meets the required standards.
  4. Employee Confidence: Providing workers with well-fitting respiratory protective equipment enhances their confidence in their workplace safety. This, in turn, can improve overall job satisfaction and productivity.
  5. Healthcare Savings: By preventing exposure to hazardous airborne contaminants, face fit testing contributes to reducing the incidence of respiratory illnesses among workers. This, in turn, leads to fewer medical expenses and less strain on healthcare systems.COSHH Regulations require testing for everyone that uses tight-fitting RPE. This applies to both reusable and disposable masks. Also, if a person uses more than one type of mask, then they will require a check for all the styles that they use.


Challenges and Considerations:

Despite its significant benefits, testing presents some challenges and considerations:

Training and Expertise: Conducting accurate face fit testing requires trained personnel who are familiar with the testing methods and equipment. Proper training is essential to ensure consistent and reliable results.

Variability: Individual facial features can vary significantly, impacting the fit of a respirator. Therefore, fit testing should be performed for each worker individually.

Maintenance: Proper care and maintenance of respiratory protective equipment are essential to ensure consistent performance. Fit testing should be conducted periodically and whenever changes in facial features occur.

Communication: Clear communication between the fit tester and the wearer is crucial during the testing process. Wearers should be instructed on the correct techniques and movements to perform during the test.


Face fit testing is an indispensable process in the realm of occupational health and safety. It ensures that respiratory protective equipment provides effective safeguarding against airborne hazards, preventing potential health risks to workers. As workplaces continue to prioritize the well-being of employees, the implementation of rigorous testing procedures becomes paramount. By investing in proper testing, employers not only adhere to regulatory standards but also prioritize the long-term health and safety of their workforce. Ultimately, ensuring masks fit properly is a testament to the commitment to creating a secure and healthy work environment in the face of evolving industrial challenges.

How do I choose a supplier?

You must choose a competent person. The best way to ensure this competency is to make sure that the person undertaking the check is certified to do so. The British Safety Industry Federation (BSIF) and the HSE have set up a scheme to certify service providers. Synergy Environmental Solutions can supply qualified and competent testers to undertake your work.

What does the the test involve?

Qualitative testing involves checking the seal of the mask during a series of seven exercises. During each activity, we use a sweet or a bitter substance to challenge it. The employee must state whether they can taste it. The result of each check gives a pass or fail result. If any of the checks fail, then the whole test fails.

Facial Hair

All tight-fitting masks rely on a good seal with the face. If the seal is not tight, then the contaminated air will pass through the gap, and the user will breathe it in. Beards make it impossible to get this seal between the mask and the skin and the face fit testing will fail.

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01782 614236 or [email protected]

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Synergy Environmental Solutions provide
sampling and consultancy services
throughout the UK and Ireland

We’re happy to answer any questions you have,
or provide you with an obligation
free estimate for work.
Just send us a message!

Tel: 01782 614236

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