PPE/Specific/TBT-PPE-026
RPE Types and Face Fit Requirements
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RPE Types and Face Fit Requirements
Respiratory protective equipment protects workers from inhaling dusts, fumes, gases, and vapours that can cause serious lung disease including silicosis, asthma, and cancer. RPE ranges from disposable FFP masks to full-face powered respirators. The key principle is that tight-fitting RPE only works if it forms a seal against the face, which requires a formal face-fit test for every wearer. Facial hair, incorrect size, and poor donning technique all compromise the seal and reduce protection to dangerous levels.
Key Hazards
Lung disease from wearing RPE that does not fit properly and allows leakage
Incorrect RPE type selected providing inadequate protection for the hazard present
Facial hair breaking the face seal and allowing contaminated air to be inhaled
Dirty or damaged filters reducing the filtration capacity of the respirator
Control Measures
- Select the correct RPE type and filter based on the COSHH assessment for the specific hazard.
- Ensure every wearer of tight-fitting RPE has passed a face-fit test for the specific mask model.
- Clean-shave the area where the mask contacts the face before every use of tight-fitting RPE.
- Check the RPE fits correctly by performing a fit check every time you put the mask on.
- Replace disposable masks after each shift or when breathing becomes noticeably more difficult.
- Store reusable RPE in a clean, sealed container when not in use to protect filters from contamination.
- Use powered air-purifying respirators where tight-fitting masks cannot achieve an adequate seal.
- Attend face-fit testing whenever your RPE model changes or your facial shape alters significantly.
- Report any difficulty breathing, skin irritation, or discomfort from RPE to your supervisor.
Remember
- Tight-fitting RPE only protects you if it forms a proper seal against your face.
- A face-fit test is a legal requirement for every person wearing tight-fitting RPE.
- Facial hair, even stubble, breaks the face seal and dramatically reduces RPE protection.
- The RPE type must match the hazard — an FFP2 mask does not protect against gases or vapours.
- Perform a fit check every time you put on your mask to confirm the seal is adequate.
- If you cannot achieve a good seal with a tight-fitting mask, a powered respirator is the alternative.
Applicable Legislation: PPE at Work Regulations 2022 · COSHH Regulations 2002 · BS EN 149 (Filtering Half Masks) · INDG479 (RPE at Work)
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