5 Reasons For A Respirator Fit Test Fail—And How to Avoid Them

Respirator fit testing is a critical step in ensuring workplace safety, especially in environments where exposure to airborne hazards is a concern. However, many workers experience fit test failures, which can delay work and compromise safety. Knowing the reasons behind these failures can help organizations take preventive measures and ensure that employees are adequately protected. Here are five common reasons why respirator fit tests fail and what you can do to avoid them.

 1. Incorrect Mask Size

One of the most common reasons for a respirator fit test failure is using a mask that is not the correct size. Respirators come in different sizes to accommodate various face shapes and sizes. A mask that is too small or too large will not seal properly, allowing contaminants to enter. 

How to Avoid It:

Ensure that employees are provided with multiple mask sizes to try during the fit test. Educate them on the importance of selecting the correct size and how to properly assess the fit.

 2. Facial Hair Interference

Facial hair, including beards, mustaches, or stubble, can interfere with the seal of a respirator, leading to fit test failure. The presence of hair under the mask prevents the respirator from making full contact with the skin, which compromises the seal.

How to Avoid It:

Implement a clean-shaven policy for employees who are required to wear tight-fitting respirators. If facial hair is unavoidable, Consider employing respirators that don’t need a tight facial seal, such as powered air-purifying respirators (PAPRs) with loose-fitting hoods.

 3. Improper Donning of the Respirator

The way a respirator is put on, or “donned,” can significantly affect its performance during a fit test. If the straps are not properly adjusted or the mask is not positioned properly on the face, it can lead to an inadequate seal.

How to Avoid It:

Provide comprehensive training on the correct donning and doffing procedures for respirators. Ensure that employees practice these techniques regularly and receive guidance during fit testing to correct any mistakes.

 4. Wearing Incorrect PPE Underneath the Mask

Other personal protective equipment (PPE), such as glasses, goggles, or head coverings, can interfere with the respirator’s seal if not worn correctly. For example, the arms of safety glasses can break the seal at the temples, leading to fit test failure.

How to Avoid It:

Conduct the fit test while employees are wearing all the PPE they would normally use during work. This ensures that any potential issues with the interaction between the respirator and other PPE are identified and addressed.

5. Physical Changes to the Face

Physical changes like weight increase or loss, dental work, or scars may all have an impact on how a respirator fit. These alterations may affect the contour of the face, resulting in poor seal and fit test failure.

How to Avoid It:

Regularly reassess the fit of respirators, especially after any significant physical changes. It’s essential to perform fit tests annually and whenever there are changes that could affect the fit of the respirator.

Conclusion

Respirator fit test failures are preventable with the right knowledge and preparation. By addressing these common issues—incorrect mask size, facial hair interference, improper donning, incorrect PPE use, and physical changes—you can improve the likelihood of a successful fit test. At Rock Solid Hazmat, we prioritize the safety and well-being of our workforce by ensuring that each employee is fully protected in their work environment. Taking the time to get it right is an investment in the health and safety of your team, and Rock Solid Hazmat is committed to upholding the highest standards in hazardous materials response.