Face Fit Testing: What the Law Requires and Why It Matters

Why Face Fit Testing Is Necessary

Respiratory protective equipment (RPE) is used to protect workers from breathing in harmful dusts, fumes, gases, and vapours. For tight-fitting masks to work, they must form an effective seal against the wearer's face. Faces vary enormously in shape and size, so a mask that fits one person well may leak badly on another. Face fit testing checks that a specific mask suits a specific wearer.

Without a good seal, contaminated air is drawn in around the edges of the mask, and the protection it offers is largely lost. This is why face fit testing is not optional where tight-fitting RPE is relied upon.

The Legal Requirements

The duty to carry out face fit testing flows from several regulations, including the Control of Substances Hazardous to Health Regulations 2002 (COSHH), the Control of Asbestos Regulations 2012, and the Control of Lead at Work Regulations 2002. Where these regulations require the use of tight-fitting RPE, the equipment must fit the wearer correctly, and fit testing is the recognised way of demonstrating this.

Fit testing should be carried out as part of the initial selection of RPE, and repeated whenever there is a change that could affect the fit, such as significant weight change, dental work, or facial surgery.

Qualitative and Quantitative Methods

There are two main types of face fit test:

Qualitative testing relies on the wearer's sense of taste or smell to detect a test agent. It is suitable for disposable masks and half masks but not for full face masks.

Quantitative testing uses specialised equipment to measure the actual leakage into the mask and produces a numerical fit factor. It is suitable for all tight-fitting masks, including full face respirators.

The Importance of Clean-Shaven Faces

Tight-fitting masks cannot seal against facial hair. Stubble or a beard along the seal line will allow contaminated air to leak in, regardless of how well the mask is otherwise selected. Workers who need to wear tight-fitting RPE must be clean shaven where the mask seals. Where employees cannot or do not wish to shave, loose-fitting alternatives such as powered hoods should be considered.

Who Can Carry Out Fit Testing?

Fit testing must be carried out by a competent person with adequate knowledge, training, and experience. The Fit2Fit accreditation scheme provides assurance that a tester has demonstrated their competence, although accreditation is not a legal requirement in itself.

Record Keeping

You should keep records of fit tests, including the make, model, and size of the mask, the test method used, the result, and the date. These records demonstrate compliance and help you manage repeat testing.

How We Can Help

We provide HSE-compliant face-fit testing at your premises across Leicestershire and the East Midlands, fitting it around your shift patterns to minimise disruption. We can also review your wider use of RPE to make sure it is suitable for the hazards your team faces. Get in touch to arrange testing or to discuss your respiratory protection arrangements.