Safe Work Procedure: Respirator Fit Testing

Document Number: [SWP-NUMBER] Revision Date: [DATE] Next Review Date: [NEXT REVIEW DATE] Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the required steps for conducting respirator fit testing to ensure employees are adequately protected when using tight-fitting respirators. It applies to all personnel required to wear respirators with negative or positive pressure tight-fitting facepieces. This procedure covers both Qualitative Fit Testing (QLFT) and Quantitative Fit Testing (QNFT) methods, detailing the requirements for each to ensure proper respirator fit and protection 4, 7.

2. Definitions

Qualitative Fit Test (QLFT): A pass/fail fit test that relies on the individual's ability to detect a challenge agent (e.g., isoamyl acetate, saccharin, Bitrex, or irritant smoke) [1].

Quantitative Fit Test (QNFT): A fit test that uses instruments to measure the amount of leakage into the respirator facepiece, providing a numerical fit factor [1].

Fit Factor: A quantitative estimate of the fit of a particular respirator to a specific individual, determined through QNFT [1].

3. Responsibilities

3.1 Supervisors

Ensure employees required to wear respirators are fit tested before initial use, whenever a different respirator facepiece is used, and at least annually thereafter 4, 7.
Ensure fit testing is conducted whenever changes in an employee's physical condition could affect respirator fit 4, 7.
Provide employees with a reasonable opportunity to select a different respirator facepiece and be retested if the fit is unacceptable 4, 7.
Ensure that persons administering QNFT are able to calibrate equipment and perform tests properly, recognize invalid tests, calculate fit factors properly and ensure that test equipment is in proper working order 5, 18.

3.2 Workers

Participate in fit testing as required by the employer 4, 7.
Report any changes in physical condition that could affect respirator fit to their supervisor 4, 7.
Perform a user seal check each time a respirator is donned [2].
Select the most acceptable respirator from a sufficient number of models and sizes 1, 9.

3.3 Health and Safety Representative

Assist in the development and implementation of the respirator program.
Monitor the fit testing program to ensure compliance with regulatory requirements.
Investigate incidents or near-misses related to respirator use and fit testing.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Poor respirator fit	Inadequate protection from airborne contaminants	Conduct proper fit testing, ensure proper respirator selection, perform user seal checks 4, 7, 16
Exposure to challenge agents (QLFT)	Irritation, allergic reaction	Use appropriate challenge agents, follow proper procedures, provide adequate ventilation [3]
Equipment malfunction (QNFT)	Inaccurate fit test results	Regularly inspect, maintain, and calibrate QNFT equipment 5, 18
Breathing difficulty during fit test	Medical condition exacerbated	Refer employee to a physician or other licensed health care professional 12, 16

5. Personal Protective Equipment (PPE)

Proper PPE must be worn during fit testing to protect the employee and the fit test administrator.

Gloves - To prevent contamination and protect skin from challenge agents.
Eye protection - Safety glasses or goggles to protect eyes from irritants during fit testing.
Respirator - The respirator being fit tested must be the correct type, size, and model for the employee and the hazard 4, 7.

Inspect PPE before each use for damage or defects. Replace damaged or defective PPE immediately.

6. Equipment and Tools

Respirators - A selection of respirators in various makes, models, styles, and sizes to ensure proper fit 1, 9.
Fit test kit (QLFT) - Includes challenge agent, hood, and sensitivity test materials [3].
Fit test equipment (QNFT) - Includes instrumentation for measuring respirator fit, such as a PortaCount 10, 13.
Mirror - To assist the test subject in evaluating the fit and positioning of the respirator 1, 9.

Inspect equipment and tools before each use for damage or defects. Follow manufacturer's instructions for proper use and maintenance 5, 18.

7. Pre-Job Requirements

7.1 Training and Competency

Employees must be trained on the proper use, maintenance, and limitations of respirators 1, 9.
Fit test administrators must be trained and competent in conducting fit tests, recognizing invalid tests, and ensuring equipment is in proper working order 5, 14, 18.

7.2 Pre-Job Briefing

Conduct a pre-job briefing to discuss the fit testing procedure, potential hazards, and control measures 12, 16.
Explain the test exercises and the test subject's responsibilities during the test procedure 12, 16.

7.3 Work Area Preparation

Ensure the fit testing area is clean, well-ventilated, and free from distractions [3].
For QNFT, ensure the test chamber is properly set up and the test agent concentration is stable 6, 8.

8. Safe Work Procedure Steps

8.1 Respirator Selection

Allow the test subject to pick the most acceptable respirator from a sufficient number of models and sizes 1, 9.
Show the test subject how to put on the respirator, how it should be positioned on the face, how to set strap tension, and how to determine an acceptable fit 1, 9.
Instruct the test subject to hold each chosen facepiece up to the face and eliminate those that obviously do not give an acceptable fit 1, 9.
Have the test subject don the most comfortable mask and wear it for at least five minutes to assess comfort 1, 9.
Review the following points with the test subject to assess comfort: Position of the mask on the nose, room for eye protection, room to talk, and position of mask on face and cheeks 1, 9.
Ensure that there is no hair growth between the skin and the facepiece sealing surface [2].

8.2 User Seal Check

The test subject shall conduct a user seal check, either the negative and positive pressure seal checks or those recommended by the respirator manufacturer which provide equivalent protection [2].
Before conducting the negative and positive pressure checks, the subject shall be told to seat the mask on the face by moving the head from side-to-side and up and down slowly while taking in a few slow deep breaths [2].
Select another facepiece and retest if the test subject fails the user seal check tests [2].

8.3 Fit Testing (QLFT or QNFT)

Administer the fit test using an OSHA-accepted QLFT or QNFT protocol 4, 7.
Ensure the test subject wears any applicable safety equipment that may be worn during actual respirator use which could interfere with respirator fit 12, 16.
Perform the required test exercises in the appropriate test environment 3, 12:
- Normal breathing
- Deep breathing
- Turning head side to side
- Moving head up and down
- Talking
- Grimace (QNFT only) [3]
- Bending over [3]
For QNFT, monitor the test agent concentration inside the respirator and terminate the test if any single peak penetration exceeds 5 percent for half masks and 1 percent for full facepiece respirators 6, 8.
After the test exercises, question the test subject regarding the comfort of the respirator 2, 11, 15.
If the respirator has become unacceptable, try another model of respirator 2, 11, 15.

9. Precautions and Safety Measures

Ensure proper ventilation in the fit testing area to minimize exposure to challenge agents [3].
Use appropriate controls to minimize the risk of exposure to the challenge agent. Follow manufacturer’s instructions and safety guidelines [3].
Do not conduct the test if there is any hair growth between the skin and the facepiece sealing surface [2].
If a test subject exhibits difficulty in breathing during the tests, refer them to a physician or other licensed health care professional 12, 16.
The respirator shall not be adjusted once the fit test exercises begin. Any adjustment voids the test, and the fit test must be repeated [3].

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop the fit testing procedure and assess the situation.
Provide first aid or medical assistance as needed.
Evacuate the area if necessary.

10.2 Specific Emergency Scenarios

Adverse reaction to challenge agent: Remove the employee from the testing area and provide fresh air. Seek medical attention if symptoms persist.
Equipment malfunction: Stop the fit testing procedure and follow the manufacturer's instructions for troubleshooting or repair.
Breathing difficulty: Remove the respirator and refer the employee to a physician or other licensed health care professional 12, 16.

10.3 Emergency Contact Information

[Emergency Contact 1] - [Phone Number]
[Emergency Contact 2] - [Phone Number]
[Emergency Contact 3] - [Phone Number]

11. Incident Reporting and Investigation

Report any incidents, near-misses, or hazards related to fit testing to the supervisor or safety department. Investigate reported incidents to determine the root cause and implement corrective actions to prevent recurrence.

12. References and Related Documents

29 CFR 1910.134 - Respiratory Protection 7, 8, 9, 12, 13, 14, 15, 18
ANSI Z88.2 - Practices for Respiratory Protection
NIOSH Respirator Selection Logic

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]