Face Fit Testing for Respiratory Protective Equipment
If employees are required to wear tight-fitting respiratory protective equipment, face fit testing is essential. It confirms that the mask provides a secure seal and offers the protection it is designed for.
THSP provides professional face fit testing in line with HSE guidance to help support compliance and, more importantly, worker safety.
Why face fit testing matters
Even a high-quality mask will not protect the wearer if it does not fit correctly. Small gaps can significantly reduce effectiveness and increase exposure to harmful substances.
Face fit testing confirms that the chosen mask fits the individual correctly and performs as required in real working conditions.
Our testing process
We carry out qualitative face fit testing in line with HSE guidance. This includes:
- Pre-test checks and health screening
- Selection of the appropriate testing method
- Conducting the fit test in controlled conditions
- Guidance on correct mask fitting and use
Arrange Face Fit Testing for your team
Ensure your RPE is providing the protection it is designed for. Contact us to schedule face fit testing at a time that works for your site operations.
Frequently Asked Questions About Face Fit Testing
What is face fit testing and why is it required?
Face fit testing confirms that a tight-fitting respiratory protective equipment facepiece, such as an FFP3 mask or half-face respirator, creates an adequate seal for the individual wearer. Even a high-quality mask will not provide the protection it is rated for if it does not fit correctly. Under HSE guidance and the Control of Substances Hazardous to Health Regulations 2002, employers are required to ensure that RPE is suitable for the wearer, which means face fit testing is a legal obligation where tight-fitting RPE is used.
Is face fit testing a legal requirement?
Yes. Where tight-fitting RPE is used as a control measure in the workplace, face fit testing is a legal requirement under COSHH and supported by HSE guidance document HSG53. Employers have a duty to ensure that RPE not only meets the required protection standard but also fits the individual correctly. Providing a mask without confirming fit does not satisfy that duty.
Who needs face fit testing?
Anyone required to wear tight or close-fitting RPE in the workplace needs to be face fit tested. This commonly includes workers in construction, manufacturing, engineering and industrial environments where exposure to dust, fumes, fibres or other airborne substances is a risk. The test must be carried out for each individual, as fit varies between people even when using the same mask model.
Do you need to shave for face fit testing?
Yes. Facial hair that passes under the seal of the mask, including stubble, will prevent it from forming an adequate seal and will result in a failed test. HSE guidance is clear that tight-fitting RPE cannot be worn effectively over facial hair. Workers should be clean shaven in the area where the mask contacts the face before attending a face fit test. THSP will advise on this as part of the pre-test process.
How often does face fit testing need to be repeated?
A face fit test should be repeated if the worker changes to a different mask model or size, if they experience significant changes to their facial structure such as weight loss or dental work, or if there is any reason to believe the original fit may no longer be valid. THSP can advise on whether a retest is needed based on your specific circumstances.
What is the difference between qualitative and quantitative face fit testing?
Qualitative testing uses the wearer’s sense of taste or smell to detect whether a test agent is passing through the seal. Quantitative testing uses equipment to measure the actual amount of leakage around the facepiece. THSP carries out qualitative face fit testing in line with HSE guidance, which is the appropriate method for most tight-fitting RPE used in construction and industrial environments.
Can face fit testing be carried out on site?
Yes. THSP can attend your site or premises to carry out face fit testing at a time that fits your operations, minimising disruption to the working day. Testing is conducted in controlled conditions and includes pre-test health screening, guidance on correct mask fitting and written records of the results.
What happens if an employee fails a face fit test?
If a worker cannot achieve an adequate fit with a particular mask, the solution is usually to try a different model or size rather than assume RPE is unsuitable altogether. THSP will provide guidance on next steps and help ensure the right equipment is identified for each individual.
What records are produced after face fit testing?
Each test produces a record confirming the individual, the mask tested, the method used and the outcome. These records are important for demonstrating compliance and should be kept as part of your wider RPE management documentation. THSP will provide written results for all tests carried out.
Does face fit testing cover all types of masks?
Face fit testing applies to tight-fitting facepieces only, including disposable FFP2 and FFP3 masks, half-face and full-face respirators. Loose-fitting RPE such as powered air-purifying respirators with hoods or helmets does not require face fit testing. If you are unsure which category your RPE falls into, THSP can advise as part of the testing process.