respirator illustration comparing respirator fit test and fit check

Respirator Fit Check vs. Respirator Fit Test

What’s the Difference?

Under OSHA’s Respiratory Protection Standard, 29 CFR 1910.134, employers are required to ensure that tight-fitting respirators properly seal to the wearer’s face. Two separate procedures are used to meet this requirement: the respirator fit check and the respirator fit test. Although these terms are often confused, they serve different purposes and both are required for Occupational Safety and Health Administration (OSHA) and Hazardous Waste Operations and Emergency Response (HAZWOPER) compliance.

Fit Check For HAZWOPER Work

A respirator fit check, also referred to as a user seal check, is a quick self-check performed by the employee every time a tight-fitting respirator is donned. The purpose of a fit check is to verify that the respirator is seated correctly on the face and that no obvious air leaks are present around the face seal. OSHA requires fit checks to be conducted at the time of use, but they are not a substitute for a formal respirator fit test.

Fit checks are typically performed using both positive pressure and negative pressure methods. During a positive pressure fit check, the wearer covers the exhalation valve and gently exhales. A proper seal is indicated when the facepiece slightly bulges without air leaking around the seal. During a negative pressure fit check, the wearer covers the inhalation openings and gently inhales while holding their breath for several seconds. The respirator should collapse slightly and remain collapsed while the breath is held. If leakage is detected during either method, the respirator must be repositioned and the fit check repeated until a proper seal is achieved.

Fit Test For HAZWOPER Work

A respirator fit test is a formal, OSHA-required procedure that determines whether a specific make, model, style, and size of respirator fits a specific individual. Fit testing must be completed before an employee uses a respirator for the first time, at least annually thereafter, and whenever changes occur that could affect respirator fit. These changes may include significant weight gain or loss, facial surgery, dental work, scarring, or switching to a different respirator model or size. OSHA requires all fit testing to be conducted in accordance with Appendix A of 29 CFR 1910.134 and to be properly documented.

Qualitative Fit Testing and Quantitative Fit Testing

There are two OSHA-approved types of respirator fit tests: qualitative fit testing and quantitative fit testing. Qualitative fit testing is a pass-or-fail method that relies on the wearer’s ability to detect a test agent, such as saccharin, Bitrex, isoamyl acetate, or irritant smoke. During a qualitative fit test, the wearer performs a series of exercises including normal breathing, deep breathing, turning the head side to side, nodding up and down, talking, and bending over. If the wearer tastes, smells, or senses the test agent at any point, the fit test is failed.

Quantitative fit testing is an objective method that uses specialized equipment, such as a PortaCount®, to measure the amount of leakage into the respirator and calculate a numerical fit factor. This method does not rely on the wearer’s senses and is often required for higher levels of respiratory protection. OSHA establishes minimum fit factor requirements, including a minimum fit factor of 100 for half-mask respirators and at least 500 to 1,000 for full-face respirators, depending on the respirator’s assigned protection factor.

It is important to understand that a respirator fit check and a respirator fit test are not interchangeable. A fit check confirms the seal of the respirator at the moment it is worn, while a fit test verifies that the respirator model itself can provide adequate protection for the individual wearer. OSHA also prohibits facial hair or other conditions that interfere with the face seal and requires employees to receive medical clearance before undergoing respirator fit testing.

Respirator Protection Program

Employers must maintain a written respiratory protection program, ensure respirator fit testing is performed and documented, and train employees on proper respirator use, fit checks, and limitations. When fit checks are performed every time a respirator is worn and fit tests are conducted in accordance with OSHA requirements, employers can significantly reduce the risk of respirator failure and improve overall worker protection.

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