COS/Specific Substances/TBT-COS-013

RPE Selection and Face Fit Testing

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RPE Selection and Face Fit Testing

Toolbox Talk Record

Ref: TBT-COS-013  |  Issue: 1  |  Date: March 2026
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What?

  • 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.

Why?

Ineffective protectionRPE that does not fit lets contaminated air leak around the seal, giving a false sense of protection.
Legal requirementCOSHH 2002 requires face fit testing for all tight-fitting RPE. Failure to test is enforceable by HSE.
Correct filter selectionUsing 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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