Going Beyond Compliance

In high-risk occupations, such as firefighting, industrial operations or regulatory inspections, it is increasingly recognized that compliance with standard fit testing protocols for respirators is not always sufficient. While quantitative fit tests remain an essential part of compliance, some organizations explore additional ways to study how respirators perform during real tasks in controlled, non-hazardous settings. These studies are sometimes referred to as respirator fit assurance efforts.

The TSI OmniCount™ Portable Water-based Condensation Particle Counter (PWCPC) Model 3002 offers​​​​​​​ features that support this type of evaluation. Its compact size, dual-channel setup, and battery-powered portability enable data collection in situations where users are simulating real-world activity – without actual exposure to hazards.

What Is Respirator Fit Assurance?

Respirator fit assurance typically refers to the use of particle counting instruments to assess respirator fit during simulated work conditions or task-specific exercises. It is distinct from quantitative fit testing, which is based on standardized protocols and pass/fail criteria.

Organizations may choose to carry out fit assurance studies to:

• Observe how respirator fit changes during specific tasks
• Examine how movement, posture, or exertion may influence protection
• Provide training feedback to improve respirator usage
• Support product development or selection processes

These evaluations are generally performed in safe, controlled environments and are not substitutes for regulatory fit tests.
 

Supporting Simulated Workplace Assessments

Because the OmniCount™ PWCPC is portable and features two synchronized sampling channels, it can be configured to monitor ultrafine particle concentrations inside and outside of a ported respirator. When worn during a simulated task, this setup may help users explore how respirator fit performs under conditions that resemble actual work movements.

Example Use Case: A team conducts a Simulated Workplace Protection Factor (SWPF) study involving participants performing ladder climbing or lifting motions while wearing ported respirators connected to the OmniCount™ PWCPC. These studies are performed in clean environments where particles are introduced in a controlled way, and respirators are not exposed to hazardous materials. The resulting data can provide insight into how task-specific motion may relate to seal integrity.
 

Training Users Based on Actual Performance Data

In addition to structured studies, some training programs may use particle monitoring to give users real-time feedback on how donning technique or task execution might affect respirator fit. The portable nature of the OmniCount™ PWCPC may support this approach by allowing measurements to be taken outside of a laboratory setting.

Example: In a training session, safety personnel observe particle concentration changes when a user talks, turns, or bends while wearing a ported respirator connected to the PWCPC. These observations are used to guide improved respirator handling and wearing techniques during future practice sessions.
 

Helping Accelerate Respirator Development

Manufacturers and researchers may find it useful to study fit performance during early-stage product development. By simulating typical user activities and capturing dual-channel particle data, they can gather information that supports design refinement and user experience optimization.
 

Testing Field Readiness Before Entering Hazardous Environments

Before entering high-risk or high-contamination environments, teams may choose to verify that respirators are donned properly and functioning as expected. In some scenarios, this includes conducting a brief check with a particle counter to confirm no signs of leakage during typical movements.

Such checks must still be done in safe environments, and respirators should not be modified (e.g., ported) in hazardous areas.
 

Respirator “Protection” Factor

Unlike traditional fit testing setups that rely on a single-channel device with a switching valve to alternately sample ambient (C_out) and in-respirator (C_in) particle concentrations used to calculate a “fit” factor, the OmniCount™ PWCPC allows for dual-channel simultaneous sampling. This capability helps enable continuous, synchronized measurement of both ambient and respirator-internal particle concentrations, which can be used to calculate a “protection” factor during real-world simulations. This side-by-side data offers valuable insight into how well a respirator performs under actual working conditions, without introducing time lags between measurements.
 

A Step Beyond Fit Testing

The TSI OmniCount™ Portable Water-based Condensation Particle Counter Model 3002 provides features that can support controlled studies of respirator performance outside the traditional fit testing environment. From training to product evaluation and simulated task assessments, it enables users to collect particle data while simulating work-like activities.

For professionals committed to worker protection, respirator performance, and operational readiness, exploring fit assurance methods may consider portable instruments like the OmniCount™ PWCPC as part of their toolkit for advancing worker safety programs and equipment evaluation efforts.

Important Notes on Use

While the OmniCount™ PWCPC allows powerful real-world analysis, it's essential to note that ported respirators used in these studies are not approved for hazardous environments or NIOSH-approved for workplace protection. All studies must be conducted in the absence of actual airborne hazards, using safe surrogates or non-toxic particles to simulate workplace conditions.

Respirator fit assurance studies using the OmniCount™ PWCPC, are not regulatory fit tests and do not replace OSHA, ISO, or EN requirements.