“A face fit test shows whether the mask you’ll use at work can maintain a seal while you breathe, speak and move.”
A face fit test is a practical assessment of how well a tight-fitting respirator fits an individual wearer.
Before the test, the tester checks the facepiece and helps the wearer put it on correctly. During the test, the wearer completes a series of breathing, talking and movement exercises. Afterwards, the tester explains the result and records the exact mask that was tested.
This guide walks through each stage of the appointment. For the wider rules on who needs testing and when it should be repeated, see our UK employer guide to face fit testing.
Quick Answer: What does a face fit test involve?
A competent tester checks the condition and fit of a specific tight-fitting mask, confirms that nothing interferes with its face seal, and guides the wearer through breathing and movement exercises. A qualitative test uses a sweet or bitter aerosol to identify leakage. A quantitative test uses an instrument to calculate a numerical fit factor. The result applies to the individual wearer and the make, model and size of facepiece tested.
Explore Velocity Safety’s on-site qualitative and quantitative face fit testing service.
Key Takeaways – The Face Fit Test Process
- Bring the exact make, model and size of tight-fitting facepiece that will be used at work.
- Facial hair must not lie between the skin and the mask’s sealing surface.
- Wear any other PPE that could affect the facepiece during the test.
- Qualitative testing checks whether the wearer detects a sweet or bitter aerosol.
- Quantitative testing measures fit with an instrument and produces a numerical result.
- A failed test means that facepiece should not be relied upon by that wearer until a suitable alternative has passed.
- A pass does not replace the user seal check required each time the mask is put on.
Jump to:
What Happens Before a Face Fit Test?
The tester first confirms which tight-fitting respirator the worker will use. Fit testing is specific to the wearer and the facepiece’s make, model and size. Testing a convenient spare mask is of little value if the worker will be issued a different facepiece for the job.
Before testing begins, the tester will normally:
- Identify the wearer and the facepiece being tested.
- Check that the facepiece is in suitable condition.
- Confirm that the wearer knows how to put it on and adjust it.
- Check that facial hair, hair, jewellery or other items do not interfere with the seal.
- Check the fit alongside any spectacles, goggles, helmet or other PPE normally worn with the mask.
- Ask the wearer to perform a user seal check after putting the mask on.
The employer should confirm that the wearer is medically fit to use the selected RPE. If there is uncertainty about suitability, an appropriate medical assessment may be needed. The fit test itself is an assessment of facepiece fit; it does not establish medical fitness or test lung function.
Does the wearer need to be clean-shaven?
The wearer must have no hair growth between the skin and the facepiece’s sealing surface. Beard growth or stubble in that area can prevent a reliable seal.
A moustache that stays completely clear of the sealing surface may be compatible with a particular mask, but the tester must assess the actual facepiece and wearer. If a worker cannot obtain a suitable seal with tight-fitting RPE, a properly selected loose-fitting hood or helmet may be an alternative.
Should the wearer avoid food, drinks or smoking?
Preparation depends on the method being used:
- Qualitative taste testing: HSE guidance says to avoid eating, drinking anything other than still unflavoured water, smoking and chewing gum for at least 30 minutes beforehand.
- Ambient particle-counting quantitative testing: The wearer should not smoke, including e-cigarettes, for at least 60 minutes beforehand.
Follow any additional preparation instructions supplied by the fit tester for the particular method and equipment.
Bring the mask and PPE used for the actual job
A pass is tied to the facepiece tested. Other head-worn PPE that could affect its fit should be worn during the assessment so any interference can be identified.
Qualitative vs Quantitative Face Fit Testing
Both methods assess whether a tight-fitting facepiece fits an individual wearer. The suitable method depends on the facepiece and the protection required.
| Feature | Qualitative Test | Quantitative Test |
|---|---|---|
| How fit is assessed | The wearer reports whether they can taste a sweet or bitter test aerosol. | An instrument measures fit and calculates a numerical fit factor. |
| Typical facepieces | Eligible disposable filtering facepieces and reusable half masks. | Disposable facepieces, reusable half masks and full-face masks, subject to the instrument and protocol. |
| Full-face masks | Not suitable. | A suitable quantitative method is required. |
| Result | Pass or fail. | A fit factor and pass or fail result. |
What Happens During a Face Fit Test?
The wearer puts on the facepiece, adjusts it and completes a user seal check. The tester then follows the protocol for the chosen fit-testing method.
Qualitative testing: the taste method
A qualitative test begins with a sensitivity check. The wearer puts on a test hood without the respirator while a weak sweet or bitter aerosol is introduced. This confirms that the wearer can detect the chosen solution.
The wearer then puts on the respirator and hood. The tester introduces the test aerosol while the wearer completes the required exercises. If the wearer tastes the solution during the fit test, it indicates that the tested facepiece has not maintained a suitable seal.
If the wearer cannot detect the solution during the initial sensitivity check, that particular taste method cannot produce a valid result for them. The tester will need to consider another suitable method.
Quantitative testing: the instrument method
A quantitative test uses suitable equipment to measure fit while the wearer completes the prescribed exercises. With an ambient particle-counting device such as a PortaCount, a small sampling tube connects the facepiece to the instrument.
The instrument produces a fit factor. The tester compares the result with the pass level required for that facepiece and method. Other quantitative technologies have different equipment and procedures, so the tester must follow the applicable protocol.
What exercises does the wearer perform?
For the standard qualitative and ambient particle-counting protocols, the wearer performs a sequence that includes:
- Normal breathing
- Deep breathing
- Turning the head from side to side
- Moving the head up and down
- Talking
- Bending over
- Normal breathing again
The movements challenge the seal in ways that resemble normal mask use. The tester gives instructions throughout; the wearer does not need to memorise the sequence. The exact exercises and timing depend on the recognised method being used.
What Happens After the Test?
The tester explains whether the specific facepiece passed or failed and documents the result.
If the mask passes
The employer should provide the same make, model and size of facepiece for the wearer’s work. The worker must continue to put it on correctly, perform a user seal check every time it is worn and report damage or problems obtaining a seal.
A passed fit test does not establish that a different mask will fit, and it does not replace routine RPE inspection and maintenance.
If the mask fails
The wearer should not rely on that facepiece for respiratory protection. The tester may check fitting technique and then assess another size or model. If suitable tight-fitting RPE cannot be found, the employer should consider another appropriate form of protection, such as a loose-fitting powered hood where suitable for the risk.
A failed result is useful information
It identifies a facepiece that should not be issued to that wearer for the intended work. Trying a different design or size can resolve the problem; simply tightening a poorly fitting mask is not a reliable solution.
What does the fit test record include?
The report should identify the wearer, date, tester, test method, exact facepiece tested and result. Depending on the method, it should also record details such as other PPE worn, the test exercises and numerical fit factors.
The employer should keep the record with its RPE documentation so the tested facepiece can be matched to the worker and the mask issued for the job.
How Long Does a Face Fit Test Take?
Allow approximately 20 to 45 minutes per person when arranging appointments. This is a planning estimate rather than a prescribed duration.
The time depends on the method, the wearer’s familiarity with the mask, preparation and whether another facepiece needs to be tried after an unsuccessful test. Ask the provider for a schedule based on the number of workers and masks being tested.
How Can Employers Prepare for a Testing Session?
Before the tester arrives:
- Identify which workers use tight-fitting RPE and which facepiece each person will wear at work.
- Make the correct makes, models and sizes available, including alternatives where possible.
- Tell staff about clean-shaven requirements and the preparation instructions for their test method.
- Ask workers to bring other PPE that they normally wear with the respirator.
- Provide a suitable space and schedule enough time for each worker.
- Confirm the employer’s arrangements for assessing whether wearers are medically fit to use the selected RPE.
- Decide how results will be recorded and how the correct masks will be issued after testing.
For the employer’s broader responsibilities, including who needs testing and when to repeat it, read What Is Face Fit Testing?
Final Takeaway
A face fit test is a guided check of a particular tight-fitting mask on a particular person. Preparation and a user seal check come first. The wearer then completes exercises while the tester assesses leakage using a taste solution or an instrument.
The outcome helps the employer issue a facepiece that has demonstrated an adequate fit. Workers must still check the seal every time they put that mask on.
Need face fit testing for your team?
Velocity Safety provides on-site qualitative and quantitative face fit testing. Tell us how many people need testing and which masks they use, and we can help plan the session.
📞 Call: 01254 933 486
📩 Email: info@velocitysafety.co.uk
🌐 Or contact Velocity Safety online.
Frequently Asked Questions
Does a face fit test hurt?
No. It is a non-invasive assessment. The wearer puts on a respirator and completes simple movements while fit is checked. Tell the tester if you feel unwell or have concerns about the test method.
What is sprayed during a qualitative face fit test?
A sweet saccharin or bitter denatonium benzoate solution is introduced as an aerosol inside a test hood. The wearer must first demonstrate that they can detect the chosen taste without the mask.
What happens if I taste the solution?
If you detect the solution during the fit test, tell the tester immediately. This indicates leakage under the qualitative protocol and the test will be recorded as a failure for that facepiece.
Do I need to be clean-shaven?
You must have no facial hair between your skin and the sealing surface of a tight-fitting mask. If you cannot achieve a reliable seal, your employer should consider another suitable facepiece or a form of RPE that does not depend on a tight face seal.
Can I be tested in a different mask from the one I use at work?
The result applies to the make, model and size tested. If your work mask differs, it needs its own fit test.
Can a full-face mask be tested using the taste method?
No. Full-face respirators require a suitable quantitative fit-testing method.
What happens if I fail?
The tester may check how you put the mask on and assess another size or model. You should not use the failed facepiece for work that depends on its respiratory protection.
Does a pass mean I can skip the daily seal check?
No. Perform a user seal check every time you put on the respirator. The formal fit test and the check before each use serve different purposes.
