Respiratory Protective Equipment (RPE) refers to devices designed to protect the wearer from inhaling hazardous airborne contaminants such as dust, smoke, fumes, gases, vapours, aerosols or infectious pathogens. It forms a critical part of workplace safety programs where engineering controls cannot fully eliminate exposure risks.
What’s covered in our guide?
Key Facts
- Primary purpose: Prevent inhalation of harmful airborne substances
- Main types: Respirators and breathing apparatus
- Typical use sectors: Construction, mining, healthcare, chemical processing, emergency response
- Regulatory standards: Health and Safety Executive, European Committee for Standardization
Types of Respiratory Protection
RPE is broadly divided into two categories: filtering devices, which clean contaminated air through a filter before it is inhaled, and supplied-air devices, which deliver clean air from an independent source. Filtering devices include disposable masks (e.g., respirators) and reusable half- or full-face respirators. Supplied-air options include airline respirators and self-contained breathing apparatus (SCBA), used in high-risk or oxygen-deficient environments.
Function and Selection
Effective respiratory protection depends on matching the device type to the hazard and ensuring a proper fit. Factors influencing selection include contaminant type, concentration, oxygen level, duration of exposure, and work environment. Fit testing, maintenance, and user training are essential for performance and compliance with safety regulations.
Common Airborne Harmful Substances may include:
- Dust
- Smoke
- Fumes
- Gases
- Vapours
- Aerosols
- Airborne pathogens
This and the work carried out/task, and the environment will govern the type of mask and the type of filter which is required to give the best protection.
Note:
We recommend that you collate the following details and consult with your PPE Provider, as they will have a dedicated competent person that will assist you in selecting the right RPE for your employees.
- What the harmful substances are
- The concentration of the airborne substance
- Its form – gas, dust, vapour etc
- And details of the task and environment in which the RPE will be worn
- Compatibility with other PPE which will be worn in the work environment
The next step depending on the type of RPE selected is to determine if the wearer will need to be Face Fit Tested & Training
Note: Suitable Employee Training on the use of PPE & RPE is required for all types.
RPE that requires Face Fit Testing
The following types of Respiratory Protective Equipment normally require Face Fit Testing and User Training because they rely on a tight seal to the face.
Disposable filtering facepieces
- FFP1
- FFP2
- FFP3
- N95-type respirators
Half-Mask Respirators
- Reusable masks with replaceable filters
Full-Face Respirators
- Cover eyes, nose, and mouth
Tight-fitting Powered Respirators
- Powered systems with close-fitting face masks
RPE that does NOT usually require face fit testing but please check with your PPE Provider.
These do not rely on a tight facial seal:
- Loose-fitting positive pressure powered hoods (with filter)
- Positive pressure helmets (with filter)
- Positive pressure visors (with filter)
- Positive pressure air-fed hoods/blouses (with filter)
However, users still need training on:
- Correct use
- Maintenance
- Battery/filter checks
- Storage and cleaning
Why do I need to be Face Fit Tested & Trained
You need to be face fit tested and trained for Respiratory Protective Equipment because a respirator only protects you if it:
- Fits your face correctly, and
- Is worn and used properly.
Why Face Fit Testing Matters
Tight-fitting masks and respirators (such as FFP3 or half-mask respirators) must seal properly against your face. If there are gaps, contaminated air can leak in around the edges.
A Face Fit Test Checks Whether
- The mask model and size suit your face – we are all different sizes and shapes
- You can achieve a proper seal
- Facial hair, glasses, or face shape affect protection
Important note about facial hair: Beards or stubble usually prevent a proper seal with tight-fitting RPE, which can cause a face fit test failure.
Why training is required?
Training helps you understand:
- How to put the respirator on correctly
- How to check the seal before use
- When filters need replacing
- Cleaning, storage, and maintenance
- The limitations of the equipment
- What hazards the RPE protects against
- Where it must be used in your work environment
Incorrect use can make the equipment ineffective even if it passed a Face Fit Test. In the UK, face fit testing for Respiratory Protective Equipment is mainly required under these health and safety regulations.
COSHH Regulations
Control of Substances Hazardous to Health Regulations 2002 (COSHH)
These regulations require employers to:
- Prevent or control exposure to hazardous substances
- Provide suitable RPE where needed
- Ensure the RPE fits properly and works effectively
Face fit testing is specifically expected for tight-fitting respirator.
Personal Protective Equipment at Work Regulations 1992
These regulations require employers to ensure PPE:
- Is suitable for the user and task
- Fits correctly
- Is maintained properly
- Comes with adequate information, instruction, and training
RPE is considered a type of PPE.
Management of Health and Safety at Work Regulations 1999
These require employers to:
- Carry out risk assessments
- Provide appropriate training
- Implement protective measures
This supports the need for RPE training and competence.
Under Health and Safety Executive Guidance, employers must ensure workers using tight-fitting RPE are:
- Properly selected for the task,
- Face fit tested, and
- Trained in correct use and maintenance.
Common Questions Regarding Face Fit Testing & Training
Who can carry out Face Fit Testing?
Face fit testing for Respiratory Protective Equipment should be carried out by a competent person who has the appropriate knowledge, training, experience, and equipment.
In the UK, Health and Safety Executive guidance says the tester should:
- Understand different types of RPE
- Know the correct testing methods
- Follow an approved fit testing protocol
- Be able to identify poor fit or unsuitable masks
- Keep proper records
Who Commonly Performs Face Fit Testing?
- Occupational Health Professionals
- Safety Consultants
- Trained in-house health & safety staff
- Specialist RPE Fit Testers
- Respiratory Protection Providers
What are the Types of Face Fit Testing?
Competent testers may perform Qualitative testing, which includes taste/smell-based tests and is commonly used for disposable FFP masks.
Or Quantitative testing, which involves using instruments to measure leakage and is often used for tight-fitting reusable respirators.
Relevant Standards and Guidance
The HSE recommends testing is carried out in line with:
- HSE guidance INDG479
- BSIF Fit2Fit accreditation scheme (widely recognised in the UK)
Fit2Fit
British Safety Industry Federation runs the Fit2Fit accreditation scheme for face fit testers. While certification is not legally mandatory, many employers prefer or require Fit2Fit-accredited testers.
Note:
The BSIF Fit2Fit Accreditation Scheme trains your designated employee to carry out Face Fit Testing & Training on your employees etc – if this is opted for you will need to purchase the testing equipment etc.
Need Face Fit Testing and Training?
At Watson & Watson Health & Safety Consultants Ltd we can offer you the Qualitative Testing Service.
This usually takes about 30 minutes per person and may depend on the following factors:
- How quickly the wearer achieves a good fit
- The type of respirator being tested
- Whether multiple mask sizes/models are tried
- Whether re-tests are required
Typical Stages
- Explanation and paperwork
- Checking the respirator fit and condition
- Sensitivity test (checking the wearer can taste/smell the test solution)
- Fit test exercises, including:
- normal breathing
- deep breathing
- head movements
- talking
- bending over
If the wearer fails the test, extra time may be needed to adjust the mask, try a different size/model or repeat the test.
For more information or call us on 01623 753 654 for a no pressure discussion on your requirements, or Face Fit Testing service page.
