The Respirator fit testing is a necessary procedure to make sure that the respiratory protection is working as intended. Even the best respirator will not protect appropriately when it is not fitted correctly. Fit testing requires some proper preparation to not only get the right results but also to comply the workplace health and safety standards.
This guide will cover some of the information you should be aware of prior to having a respirator fit test, as well as the practical dos and don’ts, personal preparation tips, and common mistakes to avoid.
Why Preparation Matters for Respirator Fit Testing
Respirator fit testing is used to determine the level to which a particular make, model and size of respirator fits the wearer. As well-known, minor factors like facial hair or recent smoking or incorrect donning can considerably affect results of the tests.
Proper preparation helps to:
- Ensure accurate and reliable fit test results
- Avoid test failures and retesting
- Confirm the respirator provides the intended level of protection
- Meet Australian WHS and AS/NZS 1715 requirements
- Save time and reduce disruption in the workplace
Preparing correctly is just as important as the fit test itself.
Pre-Test Preparation Checklist
1. Be Clean-Shaven on the day of the Fit Testing
One of the most common reasons for fit test failure is facial hair.
Before your test:
- Shave to ensure there are no hairs in the respirator interface area
- This includes stubble
- Hair must not interfere with the face seal or valve function
Even short stubble can prevent a proper seal. If facial hair cannot be removed for cultural or medical reasons, alternative respiratory protection options may need to be considered. Participants with facial hair can not be fit tested with tight fitting respirator.
2. Avoid Smoking, Vaping, or Eating Before the Test
Smoking and vaping can affect breathing patterns and may interfere with fit testing results.
Best practice:
- Avoid smoking or vaping for at least 30 minutes before the test
These steps help ensure consistent breathing and reduce potential interference during testing.
3. Avoid Wearing Makeup, Skincare Products, or Sunscreen
Products applied to the face can impact how the respirator seals.
On the day of your fit test:
- Do not wear foundation, powder, moisturiser, sunscreen, or heavy skincare products
- Keep the face clean and dry
Even thin layers of product can affect mask adhesion and test accuracy.
4. Wear Appropriate Clothing
Fit testing involves movement, including head and body exercises designed to simulate real-world conditions.
Wear clothing that:
- Allows comfortable movement
- Does not interfere with the respirator straps or head harness
- Does not obstruct breathing or test equipment
Avoid high-collared clothing, scarves, or accessories that may interfere with the fit.
5. Ensure You Are Using the Correct Respirator Model
Respirator fit testing is specific to:
- Make
- Model
- Size
- Type of respirator
Before your appointment:
- Confirm which respirator(s) you will be tested on
- Bring the respirator if required by your provider
- Ensure the respirator is in good condition and approved for use
If your workplace uses multiple respirator types, you may need to be tested on each one.
6. Be Well-Rested and Feeling Well
Your physical condition can affect test results.
Before the test:
- Get adequate rest
- Avoid strenuous activity immediately beforehand
- Inform the tester if you are feeling unwell, congested, or short of breath
If you are experiencing an illness that affects breathing, it is best to reschedule the test as we can not perform fit testing if you are experiencing respiratory illness, i.e cold, flu, cough, etc.
7. Understand the Fit Test Process
Knowing what to expect can help you perform better during the test.
Most respirator fit tests involve:
- Donning the respirator correctly
- Performing a series of movements (talking, bending, turning the head)
- Breathing normally and deeply
- Following instructions from the fit test operator
Staying calm and following instructions carefully helps achieve accurate results.
8. Be Prepared to Follow Instructions Carefully
Fit testing is a controlled process, and accuracy depends on your cooperation.
During the test:
- Do not adjust the respirator unless instructed
- Follow movement and breathing instructions exactly
- Communicate any discomfort or issues immediately
Improper adjustments during testing can invalidate results.
Common Mistakes That Lead to Fit Test Failure
Avoid these common mistakes to reduce the need for retesting:
- Arriving with facial hair in the seal area
- Wearing too much makeup or skincare products
- Smoking shortly before testing
- Using an incorrectly sized respirator
- Not following donning instructions
- Adjusting the respirator during the test
Preparation significantly reduces the likelihood of these issues.
After the Fit Test: What Happens Next?
Once testing is complete, results are recorded and provided to the employer or individual. Successful fit testing confirms:
- The respirator provides an effective seal
- The wearer can safely use that specific respirator model
- A participant will be issued a fit test certificate and a fit test card.
Fit testing must be repeated:
- At least annually
- When changing respirator models
- After significant weight change or facial surgery
- If the wearer reports fit issues
Why Professional Fit Testing Is Essential
Respirator fit testing is not just a compliance exercise – it is a critical safety measure. Proper preparation ensures the test reflects real-world conditions and confirms that workers are genuinely protected from airborne hazards.
By following this checklist, individuals and organisations can ensure fit testing is accurate, efficient, and effective.
Disclaimer – The information in this blog is for informational purposes only and is not intended as medical/financial/legal advice. Always consult with a professional before making any decisions based on this information. No guarantees or warranties are expressed by IOHC about the accuracy of the information contained in the blogs.
