Common Mistakes in Respirator Fit Testing and How to Avoid Them

Fit testing is a crucial process in ensuring the effectiveness of respiratory protective equipment (RPE) and safeguarding the health of workers. However, like any critical procedure, fit testing can be prone to errors and common mistakes. In this blog, we will address these common pitfalls and provide solutions, including the role of specialized fit testing equipment in avoiding these errors.

Mistake #1: Inadequate Training

One of the most significant mistakes in fit testing is the lack of proper training for individuals responsible for conducting the tests. Fit testing requires a deep understanding of the equipment, procedures, and regulatory requirements.

Solution: Comprehensive training is key. Ensure that fit testers receive proper instruction on the use of fit testing equipment, testing protocols, and the interpretation of results. Regular refresher training can also help maintain proficiency.

Mistake #2: Poor Fit Testing Location

Conducting fit tests in unsuitable locations can lead to poor results. Factors like poor lighting, temperature extremes, and distractions can affect the testing process.

Solution: Establish a dedicated fit test area with proper lighting, temperature control, and minimal distractions.

Mistake #3: Incorrect Equipment Selection

Using the wrong fit testing equipment for the type of respirator being tested can lead to invalid results. Different respirators require specific testing methods and equipment.

Solution: Choose fit testing equipment that is compatible with the respirators used in your workplace. Ensure that the equipment can accommodate various respirator types, including N95 masks, half-face respirators, and full-face respirators.

Mistake #4: Skipping 5-Minute Comfort Assessment Period

The OSHA required 5-minute Comfort Assessment Period is necessary to ensure that:

The respirator is comfortable to wear every time it is donned
For disposable filtering facepiece respirators that over the 5-minute period heat and moisture builds up inside the respirator increasing the seal and fit of the respirator

Solution: You must always conduct the OSHA required 5-minute Comfort Assessment Period each and every time you don a respirator whether it is for a fit test or to use the respirator in the workplace as part of a written OSHA Respiratory Protection Program.

Mistake #5: Inadequate Record-Keeping

Failure to maintain accurate records of fit test results, including details about the respirator make, model, size and employee information, can hinder compliance tracking and regulatory reporting.

Solution: Use fit testing equipment that can record and store fit test results electronically. This facilitates easy access to historical data and simplifies compliance reporting.

Mistake #6: Neglecting Maintenance and Calibration

Fit testing equipment requires regular maintenance and calibration to ensure accurate and reliable results. Neglecting these tasks can compromise the effectiveness of fit testing.

Solution: Establish a maintenance and calibration schedule for fit testing equipment, directly with the original manufacturer or an authorized service center, and adhere to it diligently. Some modern fit testing equipment can provide automated reminders for these tasks and it is important for service to be done by the original equipment manufacturer or an authorized service center.

Mistake #7: Lack of Regular Retesting

Fit testing is not a one-time event. Changes in facial features, respirator models aging with use, or work conditions can impact the fit over time. Failing to conduct regular retesting leaves workers at risk.

Solution: Implement a schedule for regular fit testing, typically annually or whenever there are changes in respirator types or facial features of employees.

The Role of Specialized Fit Testing Equipment:

Specialized fit testing equipment, such as quantitative fit testing instruments, can play a crucial role in addressing these common mistakes. They offer accurate and objective measurements, real-time monitoring, for donning and training along with automatic fit testing and data recording capabilities. Additionally, they help ensure that fit testing is conducted consistently and according to accepted regulatory standards.

In conclusion, avoiding common mistakes in fit testing is essential for maintaining a safe and healthy work environment. Comprehensive training, suitable fit test locations, proper equipment selection, 5-minute Comfort Assessment Period, meticulous record-keeping, maintenance, and regular retesting are key elements of a successful fit testing program as part of a respiratory protection program. Specialized fit testing equipment enhances the accuracy and efficiency of the process, contributing to better protection for workers and compliance with safety standards.