The Importance of Respiratory Fit Testing in Occupational Safety

March 18 2025, by Tatianna Gerard, 14 min reading time

Past pandemics have proven to us, time and again, the importance of wearing effective respiratory protection has never been clearer. But for healthcare and industrial workers, PPE isn’t just worn in response to a crisis—it’s a daily necessity.

However, simply wearing a respirator is not enough—if the mask doesn’t fit properly, it fails to provide the intended protection, leaving workers vulnerable to harmful airborne particles, bacteria, and even liquid contaminants. This is why mask fit testing is a crucial step in ensuring that PPE performs as expected in high-risk environments.

AS/NZS 1715:2009 – The standard that defines respiratory protection in Australia

When it comes to working in environments with airborne hazards—whether it’s healthcare settings dealing with infectious diseases or industrial sites exposed to harmful dust, chemicals, and fumes—having the right respiratory protection is critical. But wearing a mask alone isn’t enough.

The AS/NZS 1715:2009 is the Australian/New Zealand standard that is the key guideline for selecting, using, and maintaining respiratory protective equipment (RPE) to ensure that workers receive the highest level of protection from airborne contaminants.

What is AS/NZS 1715:2009?

AS/NZS 1715:2009, titled “Selection, Use and Maintenance of Respiratory Protective Equipment”, is an official standard designed to make sure that anyone required to wear a respirator is actually getting the protection they need.

It’s about ensuring that the mask is:

The right type of respirator for the job (e.g., N95/P2 masks for airborne infections, full-face respirators for industrial chemicals).
Properly fitted to the wearer’s face to prevent air leaks.
Well-maintained and stored correctly so it functions as intended.
Used correctly by trained workers who know how to don, doff, and care for their respirators.

Why proper mask fit matters

Imagine wearing a seatbelt that doesn’t click into place. It looks like it’s working, but in reality, it won’t protect you when you need it the most.

That’s exactly what happens when a respirator doesn’t fit properly.

AS/NZS 1715:2009 emphasises that for masks like P2/N95 respirators to work effectively, they must form a tight seal around the face. If there’s even a small gap, contaminated air can leak in, rendering the mask useless.

To ensure a secure fit, fit testing is a mandatory step—it confirms whether the mask provides an airtight seal for the individual wearer. This is particularly important for:

Healthcare workers – who need protection from airborne pathogens such as COVID-19, tuberculosis, and influenza.
Industrial workers – who are exposed to toxic fumes, dust, asbestos, and hazardous chemicals.

Types of respiratory tests

There are two types of fit testing:

1. Qualitative Fit Testing

This method relies on your senses – taste or smell – to detect leaks. A test agent, such as a flavoured aerosol or irritant smoke, is introduced into the breathing zone while you wear the respirator. You'll then perform a series of movements, like head turning or deep breathing, to simulate real-world scenarios while a trained professional observes for any signs of leakage around the respirator seal.

Qualitative fit testing is known for its simplicity and cost-effectiveness, making it a popular choice for industries with limited resources or where disposable respirators are predominantly used. Its reliance on subjective responses, however, may introduce variability, requiring careful administration by trained personnel to ensure accuracy.

2. Quantitative Fit Testing

In contrast, quantitative fit testing provides objective measurements of respirator fit by quantifying the amount of leakage that occurs between the respirator and the wearer's face. This is typically achieved using specialised equipment, such as a particle counter or a PortaCount machine that is connected to the respirator, and it measures the amount of ambient air that leaks into the facepiece during your movements. It calculates a fit factor based on the ratio of particles inside and outside the respirator.

It is particularly well-suited for industries where respirator fit requirements are stringent or where tight-fitting respirators are used, such as healthcare, manufacturing, and hazardous waste management.

Why is occupational safety especially important in certain work environments?

The nature of some workplaces inherently exposes workers to greater risks. Construction sites, laboratories, healthcare settings, and industrial facilities all have the potential to harbor airborne contaminants that can cause serious health problems. These contaminants can range from dust particles that irritate the lungs to infectious diseases that can be life-threatening.

Here's why prioritising safety in these environments is crucial:

Protecting your health - Constant exposure to harmful airborne particles can lead to a variety of respiratory illnesses, including lung cancer, chronic obstructive pulmonary disease (COPD), and asthma.
Minimising downtime - Workplace illnesses not only impact the individual's health but also lead to absenteeism and decreased productivity.
Regulatory compliance - Many industries have regulations mandating the use of respirators for specific tasks. Fit testing becomes a crucial step in demonstrating compliance with these regulations.

Several organisations and regulatory bodies oversee these standards, and specifically in Australia, it’s the Safe Work Australia, and the Therapeutic Goods Administration (TGA). Here’s what each of these regulatory bodies entails when it comes to respiratory protection and mask fit testing.

Safe Work Australia: National WHS Guidelines

Safe Work Australia is the national policy body responsible for developing and evaluating workplace health and safety (WHS) guidelines across Australia. While it doesn’t enforce laws directly, it provides a framework that each state and territory regulates and enforces through its own WHS authorities.

Key aspects of Safe Work Australia’s respiratory protection guidelines:

Provision of Personal Protective Equipment (PPE) – Employers (referred to as Persons Conducting a Business or Undertaking, or PCBUs) must provide workers with suitable PPE, including respiratory protection, when required. Employers must also ensure respirators are fit-tested for the individual worker.
Training and education – Workers must be trained on how to use, maintain, and store PPE correctly to ensure continued protection.
Workplace Exposure Standards (WES) – Safe Work Australia establishes Workplace Exposure Limits (WELs) for airborne contaminants. Workplaces must ensure that workers are not exposed to hazardous airborne substances beyond safe limits.
Fit Testing Compliance – Fit testing is strongly recommended for all tight-fitting respirators (e.g., N95/P2 masks) to ensure an airtight seal and proper protection against airborne contaminants.

More information: Safe Work Australia

Therapeutic Goods Administration (TGA) and Australian Register of Therapeutic Goods (ARTG)

What is the TGA?

The Therapeutic Goods Administration (TGA) is Australia’s regulatory body responsible for ensuring the safety, quality, and performance of medical devices, including respiratory protective equipment (RPE) like N95/P2 masks and respirators.

All masks used in healthcare settings must be TGA-approved to ensure they meet the necessary standards for filtration, breathability, and structural integrity.

What is the ARTG?

The Australian Register of Therapeutic Goods (ARTG) is part of the Therapeutic Goods Administration (TGA), Australia’s regulatory authority for medical devices, medicines, and therapeutic products. The ARTG serves as an official database where all therapeutic goods—including respirators, face masks, and other personal protective equipment (PPE)—must be registered before they can be legally supplied in Australia.

In simple terms, if a product is ARTG-listed, it has been assessed for safety, quality, and performance in compliance with Australian regulations.

NIOSH certification: What does it mean for respirators?

When shopping for respirators, you might have come across NIOSH-certified masks and wondered what this certification actually means. While NIOSH (National Institute for Occupational Safety and Health) is a United States-based organisation, its standards are often referenced globally, including in Australia, particularly when it comes to respiratory protection in high-risk workplaces.

In the US, NIOSH-certified respirators include N95 masks, which are equivalent to Australia’s P2 masks under AS/NZS 1716:2012 respiratory protection standards.

Fit test procedures and protocols

Conducting a respiratory fit test is a meticulous process that demands precision and expertise to ensure accurate results and optimal protection for workers.

While the specifics may vary depending on the chosen method (qualitative or quantitative), a typical fit test follows these general steps:

1. Initial assessment:

A qualified fit tester will review your medical history and facial features to determine if you're suitable for respirator use. They'll also take the time to explain the testing process and address any questions or concerns you may have.

2. Preparation:

Once suitability is confirmed, you'll be instructed on how to properly don the respirator. The fit tester will ensure that the respirator is adjusted correctly for your face shape and size.

3. Testing procedures:

The fit test will begin, with you performing a series of movements or exercises while wearing the respirator. Depending on the type of respiratory fit test taken, the fit tester will closely observe for any signs of leakage or discomfort around the seal.

4. Observation and documentation:

Throughout the test, the fit tester will document any observed fit issues or discomfort experienced by the wearer. Results will be evaluated against predetermined criteria to determine if the respirator provides a satisfactory fit.

5. Feedback and guidance:

After the test, you'll receive feedback on your performance and guidance on respirator selection based on the outcome. Any findings or recommendations will be documented for future reference.

Common mistakes and influential factors that might affect the testing

While it seems like a very straightforward process, respiratory fit testing can be susceptible to certain mistakes and challenges, such as:

Improper mask selection - Selecting the wrong respirator size or model can result in an improper fit. Fit testers should ensure that the chosen respirator adequately covers the nose and mouth without gaps or leaks.
Inadequate sealing - Poor sealing around the respirator edges can compromise its effectiveness. Fit testers must carefully inspect for gaps between the respirator and the wearer's face and address any issues promptly.
Incorrect positioning - Incorrect positioning of the respirator straps or nosepiece can affect the seal. Fit testers should provide guidance on proper respirator donning and adjustment techniques to ensure a secure fit.

Factors affecting fit test results may include the following:

Facial hair - Facial hair, particularly beard growth, can interfere with respirator seal integrity. Fit testers should advise individuals with facial hair to either remove it or switch to a respirator that accommodates facial hair, such as a powered air-purifying respirator (PAPR).
Weight changes - Significant weight fluctuations can affect the fit of respirators, particularly if weight loss or gain alters facial contours. Fit testers should reassess respirator fit following substantial weight changes and adjust as necessary.
Respirator models - Different respirator models may fit individuals differently due to variations in design and sizing. Fit testers should ensure that the selected respirator model is suitable for the wearer's facial features and provides a proper seal.

Why trained personnel matter

Proper fit testing hinges on qualified personnel. These individuals undergo rigorous training to ensure they:

Understand the different types of fit tests and their applications.
Can properly administer the tests following established protocols.
Can interpret the results accurately and identify any leaks.
Can guide you in selecting the most suitable respirator for your needs.

Remember, a fit test is only as good as the person administering it. Trained personnel ensure the test's accuracy, guaranteeing you receive a reliable assessment of your respirator's fit.

How often should healthcare and industrial workers get fit tested?

A poorly fitting mask can leave gaps, allowing airborne contaminants to enter and increasing the risk of exposure to hazardous particles, bacteria, and viruses. That’s why regular fit testing is essential for healthcare professionals and industrial workers who rely on respirators like P2/N95 masks for protection.

So, how often should workers get fit tested? The answer depends on workplace safety regulations, changes in facial structure, and the specific industry requirements.

Fit testing frequency: What the guidelines say

According to AS/NZS 1715:2009, fit testing should be conducted at least once a year or whenever a change in the worker’s facial structure occurs.

Here’s when workers should get re-tested:

Annually – To ensure continued protection, fit testing should be conducted at least once a year for all workers required to wear a tight-fitting respirator.
Whenever a different respirator model or size is introduced – If a new type of mask is used, a new fit test is required to confirm an airtight seal.
After significant facial changes – Factors like weight loss, weight gain, dental work, facial surgery, or facial hair growth can impact the fit of a mask, requiring a new fit test.
If a worker experiences discomfort or difficulty breathing in the mask – Any sign of leakage or improper fit means the mask needs reassessment.

Professional fit testing by Aussie Pharma Direct

At Aussie Pharma Direct, we understand the importance of workplace safety. That's why we offer professional respiratory fit testing services conducted by our team of highly trained fit testers. Our services are designed to provide peace of mind and enhanced safety for your team, adhering to the latest safety standards and regulations.

Looking to do a fit test for your team but don't have the time to travel? No problem! Our team can come directly to your workplace to conduct fit tests, minimising disruption to your workday. Contact us to schedule a day for the testing or for more information.