When Do We Need Respirator Fit Testing?

The requirement

If your workers wear tight-fitting respirators, you must ensure those respirators fit properly. This is not optional. Victorian OHS Regulations Part 4.3 requires employers to provide respiratory protective equipment that is suitable for the task and the individual worker. A respirator that does not seal correctly provides no protection.

When fit testing is mandatory

Fit testing is required before a worker first uses a tight-fitting respirator, whenever the make or model of respirator changes, and when there are changes to the worker's face that could affect the seal, including significant weight change, facial scarring, dental work, or facial hair growth.

Why fit testing matters

A respirator that does not fit leaks contaminated air into the breathing zone. Workers believe they are protected when they are not. Exposure continues. Disease develops. The employer who provided the respirator without confirming fit has failed to meet the duty under the regulations.

What fit testing involves

Quantitative fit testing uses a device to measure leakage into the respirator while the worker performs a series of movements. The test generates a fit factor score. A score above 100 indicates an adequate fit for half-face respirators. A score above 500 is required for full-face respirators. If a worker fails the fit test, a different size or model must be trialled until an acceptable fit is achieved.

Common failures

• Facial hair between the sealing surface of the respirator and the face.
• Wrong size or model selected for comfort or appearance rather than fit.
• No retesting after weight change, dental procedures, facial injuries, or other changes.

Your obligations

Provide fit testing before initial use, after any change to the respirator make or model, and after any change to the worker's face that could affect the seal. Keep records of fit test results, including the worker's name, date of test, respirator make and model, and fit factor achieved. Ensure workers who cannot achieve an adequate fit are provided with alternative respiratory protection or are not assigned to tasks requiring respiratory protection.

Consequences of non-compliance

WorkSafe Victoria prosecutions for inadequate respiratory protection have resulted in convictions and significant penalties. Workers exposed to asbestos, silica, and other carcinogens through improperly fitted respirators have developed fatal diseases. The cost of fit testing is minimal. The cost of not fit testing is measurable in prosecutions, claims, and worker health outcomes.