RPE Selection and Face Fit Testing

Respiratory protective equipment protects workers from inhaling dust, fume, vapour, and biological hazards.
RPE is a last resort under COSHH; use it only when other controls cannot adequately reduce exposure.
Disposable FFP3 masks, half-face respirators, and powered air units are the most common types on site.
Every tight-fitting RPE must be face fit tested to the individual wearer to confirm an adequate seal.
Facial hair including beards, stubble, and sideburns prevents a seal and makes tight-fitting RPE ineffective.
Qualitative fit testing uses a taste test; quantitative testing uses a particle counter for numerical results.
Face fit tests must be repeated if the wearer changes RPE model or has significant facial changes.
Powered air purifying respirators do not require face fit testing and suit workers who cannot achieve a seal.
RPE filter types must match the hazard: P3 for particles, A for organic vapour, K for ammonia.
COSHH 2002 and HSE guidance HSG53 set the legal framework for RPE selection and use.

Ineffective protection	RPE that does not fit lets contaminated air leak around the seal, giving a false sense of protection.
Legal requirement	COSHH 2002 requires face fit testing for all tight-fitting RPE. Failure to test is enforceable by HSE.
Correct filter selection	Using the wrong filter provides no protection against the specific hazard, exposing workers to serious health risks.

Do

Don't

Complete a face fit test before using any tight-fitting RPE for the first time.
Select the RPE filter type matching the specific hazard in the COSHH assessment.
Be clean-shaven in the area where the RPE seals against the face.
Carry out a user seal check every time you put on tight-fitting RPE.
Repeat the face fit test if you change RPE model or have facial changes.
Replace disposable RPE after each use or shift as the manufacturer recommends.
Store RPE in a clean, dry place away from dust and contamination.
Use powered air RPE if you cannot achieve a seal with tight-fitting masks.
Attend RPE training to understand fitting, use, and maintenance requirements.
Report any difficulty breathing or discomfort while wearing RPE immediately.

DON'T wear tight-fitting RPE if you have a beard, stubble, or facial hair.
DON'T use RPE without completing a face fit test for that specific model.
DON'T assume one RPE model fits everyone; individual face shapes vary greatly.
DON'T use a dust mask for vapour or gas hazards; select the correct filter.
DON'T reuse disposable RPE beyond the manufacturer recommended service life.
DON'T store RPE loose in a toolbox where it gets crushed and contaminated.
DON'T modify RPE by cutting, bending, or adding tape to improve the fit.
DON'T skip the user seal check when putting on tight-fitting RPE each time.
DON'T rely on RPE alone; use it alongside other COSHH controls where possible.
DON'T ignore breathing difficulty; it may indicate a poor fit or blocked filter.

See also: COSHH Awareness | Respiratory Protective Equipment (RPE)

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