Respirator Fitting & Fit Testing

Ensuring a proper respirator fit is critical for protecting workers from airborne contaminants in the workplace. At Aussie Pharma Direct, we provide certified respirator fit testing services that meet national safety standards. Our fit test process ensures that masks are both effective and comfortable. Offering fit testing Australia-wide, we help businesses maintain compliance and prioritise the health and safety of their employees through reliable respirator fit test services.

Our respirator fit testing services are designed for convenience—whether you prefer on-site testing at your facility or visiting our office, we ensure your team is properly fitted and compliant.

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What is Respirator Fit Testing?

Respirator fit testing is the process used to ensure that a respirator forms a complete seal around the wearer’s face, providing effective protection against hazardous airborne substances. Without a proper fit, even the best respirators may allow contaminants to enter, exposing workers to potential health risks. Fit testing evaluates whether the mask fits the user properly, preventing leaks and ensuring that the respirator performs as designed.

Conducted through either qualitative or quantitative methods, this testing is a critical component of workplace safety protocols, particularly in industries where workers are regularly exposed to harmful particles, chemicals, or pathogens.

Why Fit Testing?

Ensures Safety – Fit testing ensures the respirator performs effectively, reducing the risk of exposure to harmful particles and contaminants in the workplace.
Compliance with Standards – Fit testing helps businesses comply with safety regulations, ensuring that all masks meet the AS/NZS 1715:2009 standard.
Ongoing Protection – Regular fit testing guarantees that masks continue to provide protection, especially as conditions or worker needs change over time.

Who Requires Fit Testing?

Medical Professionals – Doctors, nurses, and other healthcare providers need fit testing to ensure their respirators protect them against infectious diseases and airborne contaminants.
Construction & Industry – Workers handling hazardous dust, fumes, or chemicals in industrial sectors require fit testing to prevent exposure to airborne toxins.
Research & Labs – Researchers and lab personnel dealing with dangerous substances or pathogens depend on fit testing to ensure their respirators are effective.

Why PPE Compatibility Matters in Fit Testing

The fit testing process also accounts for any other PPE that may be worn, such as safety glasses, hard hats, and hearing protection, which can interfere with the respirator’s fit. To ensure the respirator maintains a proper seal even with additional equipment, AS/NZS 1715 and ISO 16975.3 standards require all such PPE to be worn during the fit test. This precaution ensures that there are no unexpected issues with the respirator's performance when combined with other protective gear.

How is Respirator Fit Testing Done?

Respirator fit testing ensures that a respirator fits properly, creating a secure seal that protects the wearer from airborne hazards. Two methods are used for testing: qualitative and quantitative. Each method follows a specific process to evaluate the effectiveness of the respirator.

Qualitative Fit Testing (Pass/Fail Method)

Qualitative fit testing is a sensory-based method used to determine whether a respirator fits correctly. It is often applied for half-mask respirators like P2 masks, N95s or other disposable respirators, where the mask covers the nose and mouth. This test relies on the wearer’s ability to detect the presence of a test agent while performing a series of exercises.

Test agents used:

Saccharin (sweet taste)
Bitrex (bitter taste)
Isoamyl acetate (smells like bananas)
Smoke (Irritant smoke) (causes coughing or irritation if detected)

The purpose of these agents is to help detect any leaks in the respirator seal. If the wearer can sense the agent—whether through taste, smell, or irritation—it indicates that the respirator is not fitting properly.

Qualitative Fit Testing Process

1. Pre-test setup

The wearer is fitted with the respirator and checks that it feels comfortable and secure.
The fit tester explains the test and ensures that the wearer understands the importance of keeping the respirator in place throughout the test.
A sensitivity test is performed first to determine if the wearer can detect the test agent (e.g., saccharin or Bitrex) without a respirator.

2. Test exercises

The wearer is asked to perform a series of exercises designed to simulate typical movements during work, which may affect the respirator’s fit. These exercises last around 60 seconds each:

Normal breathing: Breathe in and out normally.
Deep breathing: Breathe deeply to expand the lungs and test the seal’s stability.
Turning the head side to side: Turn the head left and right, pausing briefly at each side.
Nodding the head up and down: Move the head up and down, pausing at each position to simulate looking up and down during work.
Talking: Read aloud or repeat a set phrase, such as counting backward, to simulate speaking on the job.
Bending over or moving the torso: Bend at the waist or move the torso to simulate lifting or working in different positions.

3. Using the test agent

During the exercises, the test agent (saccharin, Bitrex, or another substance) is sprayed into a hood or test environment around the wearer’s head.
The wearer continues breathing normally during the exercises.

4. Pass or Fail:

Quantitative Fit Testing (Precision Measurement)

Quantitative fit testing provides a more precise measurement of respirator fit by using instruments to measure particle leakage around the mask. This method is suitable for all types of tight-fitting respirators, including full-face masks, and is considered more accurate than qualitative testing.

Testing Instruments Used:

PortaCount: A particle-counting machine that measures the number of particles inside and outside the respirator to calculate the fit factor.
Controlled Negative Pressure (CNP): A device that creates a slight vacuum in the respirator to detect leaks.
CNC (Condensation Nuclei Counter): A device that counts ambient particles to measure any leakage into the mask.

Quantitative fit testing provides a fit factor, which is a numerical value that indicates how well the respirator fits. The higher the fit factor, the better the seal.

Quantitative Fit Testing Process

1. Pre-test setup

The respirator is fitted to the wearer as usual, ensuring comfort and proper positioning.
The respirator is then connected to the quantitative testing machine (e.g., PortaCount), which measures particle concentration inside and outside the mask.

2. Test exercises

As with qualitative testing, the wearer performs the following exercises, each lasting approximately 60 seconds:

Normal breathing: Breathe normally.
Deep breathing: Take deep breaths to simulate physical exertion.
Head movements (side to side and up and down): Move the head to simulate workplace activity.
Talking: Speak aloud to check how well the respirator fits while talking.
Bending over: Bend forward at the waist to test the fit during movement.

3. Fit factor calculation

The machine measures the concentration of particles both inside and outside the respirator while the wearer performs the exercises.
Based on these measurements, the machine calculates the fit factor, which is a ratio of particles outside the respirator to particles inside. A high fit factor means the respirator is fitting well and providing a good seal.

4. Pass or Fail

When Do We Use Qualitative vs. Quantitative?

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When Do We Use Qualitative vs. Quantitative?

What Our Fit Testing Service Offers

At Aussie Pharma Direct, we offer professional respirator fit testing services to ensure your team is safe and compliant with industry standards. We’re AOIH RESP-FIT accredited and follow the AS/NZS 1715:2009 standard, providing reliable fit testing for a range of industries.

On-Site Fit Testing: We provide fit testing at your location for added convenience, ensuring minimal disruption to your operations.
Fast and Reliable: Our service is designed to offer quick turnaround times without compromising on accuracy.
Certified Technicians: All tests are conducted by fully certified professionals with expertise in respiratory protection.
Test Methods: We use both qualitative and quantitative fit testing methods, ensuring that your workers' respirators provide the proper seal and protection they need.

If you already have respirators, you’re welcome to bring them for testing. If you’re evaluating new options, we can provide up to 5 of the most popular respirators for you to try, ensuring you select the best option.

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Employer Obligations Under WHS Law for PPE

Employers in Australia have a legal duty under the Work Health and Safety (WHS) law to protect their workers. A Person Conducting a Business or Undertaking (PCBU) must ensure the health and safety of employees by providing personal protective equipment (PPE), including respirators, when required.

Choosing the Right PPE: Employers must select respirators that minimise risk and are appropriate for the specific hazards and tasks involved.
Proper Fit: It is essential to provide PPE that fits the worker correctly, ensuring a proper seal for maximum protection.
Training Obligations: Employers are also responsible for providing training on how to use, wear, and maintain respirators properly, ensuring ongoing effectiveness and compliance.

Ensure Your Business is Compliant. Contact Us for Fit Testing Solutions.

Contact us for a quote, schedule a testing session, or ask any questions you may have about our fit testing services. We're here to help you find the best solution for your fit testing needs!

Frequently Asked Questions About Fit Testing

How often should fit testing be conducted?

In Australia, fit testing should be conducted:

Before the worker first uses a respirator.
Annually, to ensure continued proper fit.
Whenever there is a change in the worker’s facial structure, such as significant weight gain or loss, dental work, or surgery that could affect the fit.
If a new type or size of respirator is introduced.

Is respirator fit testing mandatory in Australia?

Yes, under the Work Health and Safety (WHS) law, respirator fit testing is mandatory in workplaces where tight-fitting respirators are required to protect workers from airborne hazards. The AS/NZS 1715:2009 standard outlines the requirements for fit testing, which include conducting the test before the worker first uses the respirator and annually thereafter.

What types of respirators need to be fit tested?

Fit testing is required for any tight-fitting respirators that rely on a proper seal around the face to provide protection. These respirators are classified by the level of protection they offer and include the following:

P1 Respirators: These are low-level protection respirators designed to filter out low levels of dust and particulates. Fit testing is required for P1 masks, especially in industries such as woodworking or construction where exposure to dust particles is common.
P2 Respirators & Masks (N95 Equivalent): P2 masks are the most commonly used for protection against moderate levels of airborne contaminants, including dust, fumes, and biohazards like viruses. These masks are commonly used in healthcare and industrial settings. Fit testing is required to ensure a proper seal, especially since these masks are used in environments with moderate exposure risk.
P3 Respirators: These provide the highest level of protection, designed for workplaces where workers are exposed to highly hazardous airborne particles such as asbestos or toxic dust. Fit testing is crucial for these respirators to ensure that they offer the maximum level of protection in high-risk environments.

The following types of tight-fitting respirators across different levels require fit testing:

N95/P2 masks (disposable half-face respirators)
Elastomeric half-face respirators
Elastomeric full-face respirators
Powered Air-Purifying Respirators (PAPRs) with tight-fitting facepieces

Loose-fitting respirators, such as hoods and helmets, do not require fit testing since they do not depend on a tight seal to protect the wearer.

What happens if a worker fails a fit test?

If a worker fails a fit test, it means the respirator does not create a proper seal on their face. In this case, the following steps should be taken:

Adjust the respirator and try the test again
If adjustments do not work, try a different size or model of respirator
Repeat the fit test with the new respirator to ensure it fits properly. A worker must pass the fit test before they are allowed to use the respirator in hazardous environments.

Can facial hair affect respirator fit?

Yes, facial hair, particularly around the sealing area of the respirator, can significantly affect the fit. Beards, stubble, or even long sideburns can interfere with the mask's seal, causing leaks and reducing its effectiveness.

The AS/NZS 1715:2009 standard requires workers to be clean-shaven in the area where the respirator seals to ensure a proper fit during the test and in actual use.

What is the role of the employer in ensuring fit testing is conducted?

Under WHS law, employers (PCBU) have a legal obligation to ensure that workers using tight-fitting respirators undergo fit testing. Employers must:

Provide appropriate PPE that fits the worker and is suitable for the task
Ensure fit testing is conducted before use, annually, or when changes occur (e.g., new respirators or changes in the worker's facial structure)
Offer training on the proper use, wearing, and maintenance of the respirators
Keep records of the fit tests for compliance purposes

Can fit testing be done on-site?

Yes, Aussie Pharma Direct offers on-site respirator fit testing to ensure convenience and efficiency, especially for larger companies or groups. Our certified professionals can visit your workplace, making it easier to test multiple workers in one session without disrupting your operations. On-site testing is ideal for ensuring your team is compliant with safety regulations while saving time.

For smaller companies or individual workers, we also offer the flexibility to choose between on-site fit testing at your location or visiting our office for testing. This allows you to select the most convenient option for your needs.

Do I need to bring my own mask for the fit test, or will it be provided?

You are welcome to bring your own mask for the fit test, whether it’s a personal respirator or one issued by your company. If you're exploring other options or looking to find the best fit, Aussie Pharma Direct can also provide up to 5 alternatives of the most popular respirators for you to try during the fit test. This allows you to choose the mask that provides the best protection and comfort for your needs.

What documentation is required after a fit test?

After a fit test, employers should keep detailed records of each worker’s test results, including:

The type of respirator tested (make, model, size)
The fit testing method used (qualitative or quantitative)
The fit factor (for quantitative tests)
The date of the fit test
The name of the person who conducted the test.

These records should be kept on file to demonstrate compliance with WHS regulations and to schedule future tests.

Can I wear the same respirator if I change jobs or roles?

If your new role involves different exposure risks or requires a different type of respirator, you may need to undergo another fit test. Even if you're using the same respirator model, significant changes in tasks, environments, or even facial structure may require a new test to ensure the respirator still fits properly.

Is there a difference between fit testing and user seal checks?

Yes, there is an important distinction. Fit testing is a formal process done by a trained professional to verify the respirator’s seal and is required before using a respirator. User seal checks, on the other hand, are quick checks performed by the wearer each time they put on the respirator to ensure that it is positioned and sealed correctly. Seal checks do not replace fit testing.