Frequently Asked Questions
FAQS
Face Fit Testing & Training – Frequently Asked Questions
At RPE Face Fit Solutions, we take pride in being Fit2Fit accredited, assessed by the BSIF to demonstrate competence. Our services are delivered exclusively by accredited professionals, ensuring a flexible, high-quality approach tailored to your specific needs.
Below, you'll find answers to some of the most frequently asked questions about Face Fit Testing and Training. If you don’t see the information you need, please don’t hesitate to reach out—we’re happy to help!
Contact us by email or phone to discuss your requirements. We’re here to support your team’s safety and compliance every step of the way.
Why Do I Need to Be Clean-Shaven for Face Fit Testing
For tight-fitting respiratory protective equipment (RPE) to provide an effective seal, the area where the mask meets the skin must be free from facial hair. Being clean-shaven ensures a proper fit, allowing the mask to create an effective seal, which is essential for protecting against hazardous airborne particles.
Key Reasons for Being Clean-Shaven:
✔ Prevents Leaks – Facial hair can break the seal of the mask, allowing contaminants to enter.
✔ Ensures Compliance – Health and safety regulations, including HSE guidance, require a proper seal for effective protection.
✔ Optimizes Protection – A clean-shaven face ensures the RPE works as intended, keeping you safe from harmful substances.
If you require a beard-friendly option, consider loose-fitting RPE, such as powered air purifying respirators (PAPR), which do not rely on a tight face seal.
Need further guidance? Get in touch with us—we’re happy to help!
What is Face Fit Testing & What Does the Law Say?
Face Fit Testing is a legal requirement for anyone who wears tight-fitting respiratory protective equipment (RPE), such as FFP3 masks, half masks, or full-face respirators. The test ensures that the mask forms a proper seal against the wearer’s face, preventing hazardous substances from leaking into the breathing zone.
There are two types of Face Fit Testing:
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Qualitative Face Fit Testing – A pass/fail test using a bitter or sweet-tasting aerosol to detect leaks (suitable for disposable and half-face masks).
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Quantitative Face Fit Testing – Uses specialized equipment to measure actual leakage and provide numerical results (used for all tight-fitting masks, including full-face respirators).
What Does the Law Say?
In the UK, Face Fit Testing is required under The Control of Substances Hazardous to Health Regulations (COSHH) 2002, The Personal Protective Equipment at Work Regulations 1992, and The Health and Safety at Work Act 1974.
Whys is Face Fit Testing Important?
What is Face Fit Testing & What Does the Law Say?
Face Fit Testing is critical for worker safety because poorly fitting respiratory protective equipment (RPE) fails to provide adequate protection, exposing workers to harmful airborne contaminants. Ensuring a proper fit helps prevent serious respiratory diseases caused by hazardous substances in workplaces such as construction, manufacturing, healthcare, and chemical industries.
The Risks of Poor Fitting RPE
Without a proper seal, airborne hazards—including dust, fumes, and infectious agents—can leak into the breathing zone, increasing the risk of serious health conditions such as:
✔Silicosis – Caused by inhaling respirable crystalline silica (RCS), leading to lung scarring.
✔Asbestosis & Mesothelioma – Chronic lung diseases caused by asbestos exposure, often fatal.
✔Chronic Obstructive Pulmonary Disease (COPD) – Long-term lung damage linked to exposure to fumes and dust.
✔Occupational Asthma – Triggered by exposure to substances like flour, wood dust, or chemical fumes.
Respiratory Disease Statistics
Workplace lung diseases are a major cause of occupational ill health in the UK. According to the Health and Safety Executive (HSE):
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12,000 workers die annually from past exposure to workplace airborne hazards.
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17,000 new cases of lung or breathing problems are reported each year.
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3,000+ deaths per year are linked to asbestos exposure, which remains a significant risk.
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400,000+ working days are lost annually due to occupational lung diseases.
Who Needs Face Fit Testing & How Often Should it be Done?
Face Fit Testing is a legal requirement for anyone who wears a tight-fitting respirator as a control measure in the workplace to protect against exposure to hazardous airborne substances. This includes individuals using respirators as part of their COSHH (Control of Substances Hazardous to Health) compliance, risk assessments, and workplace safety measures.
If a respirator is being relied upon to control exposure to dust, fumes, vapors, biological agents, or other hazardous substances, it must be fit-tested to ensure an effective seal and protection for the wearer.
Face Fit Testing applies to workers across various industries, including:
✔ Construction & Demolition – Those exposed to silica dust, asbestos, and other airborne contaminants.
✔ Healthcare & Emergency Services – Workers wearing FFP3 masks to prevent infection transmission.
✔ Manufacturing & Engineering – Employees exposed to welding fumes, metal dust, or chemical vapors.
✔ Woodworking & Joinery – Individuals working with sawdust, MDF, or formaldehyde-containing products.
✔ Paint Sprayers & Coating Specialists – Professionals working with solvent-based paints and coatings.
✔ Pharmaceutical & Laboratory Staff – Employees handling hazardous chemicals or biological materials.
✔ Agricultural & Pest Control Workers – Those exposed to pesticides, fertilizers, or organic dust.
Legal Compliance & Employer Responsibilities
Under UK law, including COSHH 2002, PPE Regulations 1992, and the Health and Safety at Work Act 1974, employers must ensure that RPE is fit-tested and properly maintained when used as a primary control measure.
Face Fit Testing must be carried out:
✔ Before first-time use of a respirator in the workplace.
✔ If a worker changes their mask model, brand, or type.
✔ If facial features change due to weight loss, surgery, or dental work.
✔ As part of routine health & safety compliance measures.
If a worker has facial hair, tight-fitting masks will not provide adequate protection. Alternative solutions, such as powered air-purifying respirators (PAPR), should be considered.
Certain high-risk substances have their own specific regulations regarding the frequency of Face Fit Testing due to the severe health risks involved:
🔹 Asbestos – Under the Control of Asbestos Regulations 2012, workers must be fit-tested before using RPE and tested regularly if exposure risks continue.
🔹 Ionising Radiation – The Ionising Radiations Regulations 2017 (IRR17) require strict RPE testing when working with radioactive substances that could pose inhalation risks.
🔹 Lead – The Control of Lead at Work Regulations 2002 (CLAW) mandates the use of properly fitted RPE for workers exposed to airborne lead, with regular testing intervals advised.
For these high-risk substances, regular re-testing is recommended to ensure ongoing protection and compliance.