Face Fit Testing: Checking the Right Fit for RPE

Respiratory protective equipment is essential, but the mask must suit the person using it. People have different face shapes and sizes, and masks that fit one person comfortably may not fit another. At Train in Health and Safety Ltd., we offer face fit testing for employees who must use close-fitting respiratory protective equipment (RPE). The main idea behind the testing is simple: to see whether a good face seal is possible.
Why Face Fit Testing Matters
Proper-fitting RPE requires proper contact between the mask and the individual’s face. If any air leaks along the seal, contaminated air can enter the mask. Face fit testing determines whether the chosen facepiece is appropriate for the individual user. Face fit testing is required in cases where workers need respiratory protection against workplace hazards including:
- Dust
- Fumes
- Mists
- Vapours
- Airborne contaminants
Face fit testing is very individualized and relates only to the person wearing the mask. One should not assume that because a mask fits one person, it will automatically fit another.
What Happens During Testing?
During face fit testing, we test the tightness of fit for the RPE worn by the employee. Procedures vary depending on the facepiece type and the test conducted.
The individual must then perform certain exercises while the facepiece is still on. This helps determine the seal’s effectiveness when the person performs the movements they would likely make during their work. The exercises include the following:
- Normal breathing
- Deep breathing
- Head movement
- Talking
- Moving
- Breathing normally
The Individual Fit Matters
No single facepiece will fit everyone. Different facial shapes, sizes, and features can affect facepiece fit. Therefore, we would conduct a face fit test for each user, based on the specific make, model, type, and size of the facepiece being tested.
If an employee uses multiple types of snugly fitting facepieces, the company must assess whether they need testing. This individualized approach helps ensure employers avoid the trap of assuming a universal face-fit solution.
Facial Hair And RPE
Facial hair may affect the RPE seal. Facial hair such as a beard, stubble, or any hair between the face and the sealing area could affect the mask fit. To take part in the face fit test, employees must be eligible for the specific facepiece tested.


Who Needs Testing?
Face fit testing applies to staff who have to wear tight-fitting RPE to reduce workplace exposure to hazards. Our fit testing will be useful to help workers in various industries, such as:
- Construction
- Engineering
- Manufacturing
- Maintenance
- Warehousing
- Facilities Management
- Cleaning
- Other environments where there is air contamination
RPE is one method of controlling workplace exposure, and the company should use it as part of its overall strategy. When tight-fitting RPE is used, then the fit should be considered.
When Is Retesting Needed?
A passing face fit test result does not guarantee a tight fit for that worker in the future. There is a need for another test when:
- A new make/model is adopted
- There is a change in the size of the facepiece
- The worker has changed in their facial characteristics
- Changes in dentistry or other factors may affect fit
- There are issues concerning fit
Face Fit Testing For Businesses
At Train in Health and Safety Ltd., we provide face fit testing, not face fit training. We offer this service to businesses that need fit testing for employees wearing tight-fitting respirators. The way we can help our clients is by:
- Performing face fit testing for employees
- Verifying the chosen facepiece on the employee
- Finding out whether a specific facepiece fails to give the required fit
- Giving the appropriate test result
- Helping workplaces with RPE arrangements

Why Choose Train in Health and Safety Ltd?
We offer hands-on workplace health and safety solutions for businesses and their employees. Face fit testing is simple: we test your employees. We offer face fit testing to help an organisation test the fit of tight-fitting RPE before an employee uses it for workplace protection. Whether it’s an individual worker who needs testing or a whole workplace team, we can discuss your business needs and schedule the appropriate testing.
Get Your Employees Face Fit Tested
RPE should protect the nose and mouth and fit each person who uses it. If tight-fitting RPE is required, it must fit the particular employee properly. If your company requires face fit testing for tight-fitting RPE, Train in Health and Safety Ltd. can help you. Get in touch, and we will make sure your employees’ RPE is properly fitted.
- FAQ’S
What is Face Fit Testing?
It determines whether a particular tight-fitting face piece provides an adequate fit for the specific user.
Do you offer face fit training?
No, we do face fit testing for workers who are supposed to wear tight-fitting RPE.
Who requires face fit testing?
Those who are supposed to use tight-fitting RPE may require the test.
Is facial hair a problem for face fit testing?
Yes, because facial hair within the sealing surface may inhibit a tight-fitting face piece from sealing properly.
One face fit testing for all masks?
No, because the test concerns the individual user and the particular face piece tested.
Under what circumstances would you require another face fit test?
This will require re-testing where there has been a change of face piece or any changes to the individual’s facial characteristics.
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