The simple answer is yes, in many situations it is. UK health and safety legislation requires employers to ensure that respiratory protective equipment (RPE) fits the wearer correctly whenever it is relied upon to protect against hazardous substances.
In this guide, we'll explain the legal requirements for face fit testing, how it relates to COSHH regulations, whether disposable masks need testing, and how often face fit testing should be repeated.
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Is Face Fit Testing a Legal Requirement?
One of the most common questions asked is "Is face fit testing a legal requirement?"
Where employees wear tight-fitting respiratory protective equipment (RPE) to protect themselves from hazardous substances, employers have a legal duty to ensure the equipment provides an effective seal.
This requirement comes from the Health and Safety Executive and is supported by several pieces of legislation, including:
- Control of Substances Hazardous to Health Regulations 2002 (COSHH)
- Personal Protective Equipment at Work Regulations 1992 (as amended)
- Management of Health and Safety at Work Regulations 1999
The HSE clearly states that anyone required to wear tight-fitting RPE should undergo a face fit test before using the equipment in the workplace.
Official HSE guidance is available here:
https://www.hse.gov.uk/respiratory-protective-equipment/fit-testing-basics.htm
What Is Face Fit Testing?
Face fit testing is a procedure that checks whether a respirator creates an effective seal against the wearer's face.
Even high-quality respiratory protective equipment cannot provide adequate protection if air can leak around the edges of the mask.
The purpose of a face fit test is to confirm that:
- The correct mask has been selected
- The respirator fits the individual wearer
- Hazardous substances cannot bypass the mask seal
- The wearer receives the expected level of protection
Every person's facial features are different, which is why one mask model may fit one employee but not another.
Face Fit Testing and COSHH Regulations
Many people search for information about face fit testing COSHH regulations.
Under the Control of Substances Hazardous to Health Regulations 2002 (COSHH), employers must adequately control exposure to hazardous substances.
Where respiratory protective equipment is selected as part of those control measures, COSHH requires employers to ensure:
- Suitable RPE has been selected
- Equipment is compatible with the work being carried out
- Employees receive appropriate training
- Equipment is maintained
- Tight-fitting respirators have been face fit tested
Face fit testing is therefore an important part of COSHH compliance and helps employers demonstrate they have taken reasonable steps to protect employees.
Official COSHH guidance can be found here:
https://www.hse.gov.uk/coshh/
Face Fit Testing Regulations
The legal requirements surrounding face fit testing are based on the principle that respiratory protective equipment must be both adequate and suitable.
Employers should also ensure that:
- Workers know how to wear their respirator correctly
- Daily pre-use fit checks are carried out
- Respirators are maintained according to manufacturer guidance
- Filters are replaced when required
- Records of face fit testing are maintained
Face fit testing should always be carried out by a competent person using an approved testing method.
Another common question is "Is face fit testing a legal requirement for disposable masks?"
The answer depends on the type of mask being used.
If the disposable mask is a tight-fitting respirator, such as an FFP2 or FFP3 mask, and it is being relied upon to protect the wearer from hazardous substances, then yes, face fit testing is normally required.
This includes many disposable masks used during:
- Asbestos work
- Silica dust exposure
- Construction activities
- Woodworking
- Manufacturing
- Demolition
- Pharmaceutical work
Loose-fitting powered respirators that do not rely on a face seal generally do not require face fit testing.
How Often Is Face Fit Testing Required?
One of the most frequently asked questions is "How often is face fit testing required?"
There is no fixed legal expiry period for a face fit test. However, testing should be repeated whenever:
- A different make or model of respirator is introduced
- A different mask size is used
- Significant facial changes occur
- Weight changes significantly
- Facial surgery has taken place
- Extensive dental work affects facial shape
- The wearer grows or removes facial hair that affects the seal
Many employers also choose to repeat face fit testing periodically as part of their respiratory protection programme to ensure continued compliance.
Respiratory protective equipment is often the last line of defence against hazardous substances.
Without a proper seal, harmful particles can bypass the mask entirely, reducing protection and increasing the risk of exposure.
Face fit testing helps protect workers from hazards including:
- Asbestos fibres
- Silica dust
- Welding fumes
- Wood dust
- Chemical vapours
- Biological contaminants
- Airborne particles
Combined with appropriate training and maintenance, face fit testing plays a vital role in protecting worker health.
Who Needs Face Fit Testing?
Face fit testing is commonly required for workers in:
- Construction
- Demolition
- Asbestos removal
- Manufacturing
- Engineering
- Healthcare
- Utilities
- Pharmaceutical industries
- Facilities management
Any worker required to wear tight-fitting respiratory protective equipment should be assessed before relying on the mask for protection.
Face Fit Testing at One Stop Safety Training
At One Stop Safety Training, we provide professional face fit testing services to help businesses comply with current health and safety legislation and COSHH requirements.
Our competent testers carry out recognised qualitative and quantitative face fit testing for a wide range of respiratory protective equipment, helping employers ensure workers receive the protection their masks are designed to provide.
Whether you require testing for a single employee or an entire workforce, we can help you remain compliant while improving workplace safety and protecting your team from harmful airborne hazards.
https://www.onestopsafetytraining.com/courses/Face%20Fit%20Testing
