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 steps for conducting respirator fit testing to ensure employees are properly protected when using tight-fitting respirators. It applies to all personnel required to wear respirators as part of their job duties. This procedure covers both Qualitative Fit Testing (QLFT) and Quantitative Fit Testing (QNFT) methods, detailing the requirements for each. This SWP should be used in conjunction with the site's overall Respiratory Protection Program.

2. Definitions

Qualitative Fit Test (QLFT) A pass/fail fit test method that relies on the test subject's senses to detect leakage of a challenge agent into the respirator [1].

Quantitative Fit Test (QNFT) A fit test method that uses instruments to measure the amount of leakage into the respirator and provides a numerical fit factor [1].

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

User Seal Check An action conducted by the respirator wearer each time they don the respirator to ensure a proper seal is achieved [2].

3. Responsibilities

3.1 Supervisors

• Ensure workers who are required to wear respirators are fit tested according to this procedure [3].
• Ensure that fit testing is conducted prior to initial use of a respirator, whenever a different respirator facepiece is used, and at least annually thereafter 3, 4.
• Ensure that workers are provided with respirators that fit properly and are comfortable to wear [4].
• Inform the respirator program administrator of any changes in an employee's physical condition that could affect respirator fit [3].

3.2 Workers

• Participate in fit testing as required [4].
• Select a respirator that provides the most acceptable fit [4].
• Perform a user seal check each time a respirator is donned [2].
• Report any changes in physical condition that could affect respirator fit to their supervisor [3].

3.3 Health and Safety Representative

• Assist in the development and implementation of the Respiratory Protection Program.
• Provide guidance on the selection, use, and maintenance of respirators.
• Investigate incidents related to respirator use and recommend corrective actions.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Poor respirator fit	Inadequate protection from airborne contaminants	Conduct fit testing to ensure proper fit 3, 4. Select the correct size and model of respirator [4]. Perform user seal checks each time the respirator is donned [2].
Exposure to test agents (QLFT)	Irritation, allergic reaction	Conduct odor threshold screening prior to fit testing [5]. Use the lowest concentration of test agent possible [6]. Ensure adequate ventilation in the testing area [6].
Improper use of equipment	Inaccurate fit test results	Ensure personnel administering QLFT and QNFT are trained and competent 12, 19. Calibrate and maintain equipment according to manufacturer's instructions [7].
Facial hair	Facepiece seal leakage	Enforce policy prohibiting facial hair that interferes with the facepiece seal 2, 9.
Changes in physical condition	Facepiece seal leakage	Conduct additional fit tests when changes in an employee's physical condition could affect respirator fit 3, 4.

5. Personal Protective Equipment (PPE)

Proper PPE must be worn during fit testing to protect the employee and the tester. This may include:

• Safety glasses - To protect eyes from irritants during fit testing.
• Gloves - To prevent contamination and protect skin from contact with test solutions.
• Respirator - The respirator being fit tested.

Inspect all PPE before use to ensure it is in good condition. Replace any damaged or defective PPE.

6. Equipment and Tools

The following equipment and tools may be required for respirator fit testing:

• Fit test kit (for QLFT) - Includes test solutions, nebulizers, hoods, and other necessary equipment 12, 14, 15.
• Quantitative fit testing equipment (for QNFT) - Includes aerosol generators, particle counters, and computer systems [7].
• Respirators of various makes, models, styles, and sizes - To ensure an acceptable fit can be achieved 1, 6.
• Mirror - To assist the test subject in evaluating the fit and positioning of the respirator 1, 6.
• Cleaning supplies - For cleaning and disinfecting respirators and equipment [8].

Inspect all equipment before use to ensure it is in proper working order. Follow the manufacturer's instructions for calibration, maintenance, and use.

7. Pre-Job Requirements

7.1 Training and Competency

• All personnel conducting fit testing must be trained and competent in the proper procedures for QLFT or QNFT 12, 19.
• Training must include the proper use, maintenance, and limitations of the fit test equipment.
• Employees must be trained on the proper donning, doffing, and user seal checking procedures for respirators [2].

7.2 Pre-Job Briefing

• Conduct a pre-job briefing with the employee to explain the fit testing process and their responsibilities 8, 11.
• Explain the purpose of the fit test, the type of test being conducted, and the exercises that will be performed 8, 11.
• Answer any questions the employee may have.

7.3 Work Area Preparation

• Ensure the fit testing area is clean, well-ventilated, and free from distractions 12, 15.
• For QLFT, the testing area should be separate from the odor threshold screening area [5].
• Ensure all necessary equipment and supplies are readily available.

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, 6.
• 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, 6.
• Instruct the test subject to hold each chosen facepiece up to the face and eliminate those that obviously do not give an acceptable fit [4].
• The more acceptable facepieces are noted in case the one selected proves unacceptable; the most comfortable mask is donned and worn at least five minutes to assess comfort [4].
• Assessment of comfort shall include a review of the following points with the test subject and allowing the test subject adequate time to determine the comfort of the respirator [4]:
  • Position of the mask on the nose
  • Room for eye protection
  • Room to talk
  • Position of mask on face and cheeks
• The following criteria shall be used to help determine the adequacy of the respirator fit 5, 8:
  • Chin properly placed
  • Adequate strap tension, not overly tightened
  • Fit across nose bridge
  • Respirator of proper size to span distance from nose to chin
  • Tendency of respirator to slip
  • Self-observation in mirror to evaluate fit and respirator position
• 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 5, 8.
• 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 5, 8.
• Another facepiece shall be selected and retested if the test subject fails the user seal check tests 5, 8.
• Safety Considerations: Ensure the test subject does not have any facial hair that interferes with the respirator seal 2, 9. If the employee finds the fit of the respirator unacceptable, the test subject shall be given the opportunity to select a different respirator and to be retested 8, 11.

8.2 Qualitative Fit Testing (QLFT)

• Odor Threshold Screening (for Isoamyl Acetate Protocol)
  • Perform odor threshold screening to determine if the individual tested can detect the odor of isoamyl acetate at low levels [5].
  • If the test subject is unable to correctly identify the jar containing the odor test solution, the IAA qualitative fit test shall not be performed [9].
• Fit Test Exercises
  • The test subject shall don the selected respirator and perform the following exercises inside the fit test chamber 11, 18:
    • Normal breathing
    • Deep breathing
    • Turning head side to side
    • Moving head up and down
    • Talking (reading Rainbow Passage) 11, 18
    • Bending over 11, 18
  • Each test exercise shall be performed for one minute 12, 18.
• Test Administration
  • Administer the QLFT according to the chosen protocol (Isoamyl Acetate, Bitrex, or Irritant Smoke) 12, 14, 15.
  • Monitor the test subject for any signs of leakage or irritation [6].
  • If the test subject detects the challenge agent, the fit is deemed unsatisfactory and a different respirator shall be tried 14, 15.
• Safety Considerations: Ensure the test area is well-ventilated 12, 15. Take precautions to minimize the test subject's exposure to irritant smoke [6].

8.3 Quantitative Fit Testing (QNFT)

• Preparation
  • Ensure the QNFT equipment is properly calibrated and maintained [7].
  • Attach a sampling probe to the respirator facepiece 2, 9.
• Fit Test Exercises
  • The test subject shall don the selected respirator and perform the following exercises inside the test chamber 11, 18:
    • Normal breathing
    • Deep breathing
    • Turning head side to side
    • Moving head up and down
    • Talking (reading Rainbow Passage) 11, 18
    • Grimace 11, 18
    • Bending over 11, 18
    • Normal breathing 11, 18
  • Each test exercise shall be performed for one minute except for the grimace exercise which shall be performed for 15 seconds 12, 18.
• Test Administration
  • Conduct the QNFT according to the chosen protocol (Generated Aerosol, Ambient Aerosol, or Controlled Negative Pressure) [7].
  • Monitor the fit factor throughout the test [3].
  • The test shall be terminated whenever any single peak penetration exceeds 5 percent for half masks and 1 percent for full facepiece respirators [10].
  • The test subject shall be refitted and retested [10].
• Safety Considerations: Ensure the test subject is not exposed to test agents in excess of established exposure limits [11]. Take into account the limitations of instrument detection when determining the fit factor [11].

9. Precautions and Safety Measures

• Medical Evaluation: Ensure employees have been medically evaluated and cleared to wear a respirator prior to fit testing [1].
• Facial Hair: Prohibit facial hair that comes between the sealing surface of the facepiece and the face or that interferes with valve function 2, 9.
• Corrective Lenses: Ensure that corrective glasses or goggles are worn in a manner that does not interfere with the seal of the facepiece 2, 9.
• User Seal Check: Ensure employees perform a user seal check each time they put on the respirator 2, 5, 9.
• Respirator Maintenance: Maintain respirators in proper working order and inspect regularly for deficiencies [11].

10. Emergency Procedures

10.1 General Emergency Response

• In the event of an emergency, immediately stop the fit testing procedure.
• Evacuate the area if necessary.
• Provide first aid as needed.
• Report the incident to the supervisor and health and safety representative.

10.2 Specific Emergency Scenarios

• Adverse Reaction to Test Agent: Remove the respirator and provide fresh air. Seek medical attention if symptoms persist.
• Equipment Malfunction: Stop the test and repair or replace the equipment before continuing.
• Medical Emergency: Call for medical assistance and provide first aid until help arrives.

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

• All incidents, near-misses, and hazards related to respirator fit testing must be reported to the supervisor and health and safety representative.
• An investigation will be conducted to determine the root cause of the incident and implement corrective actions to prevent recurrence.

12. References and Related Documents

• Occupational Safety and Health Standards (OSHA) 29 CFR 1910.134
• ANSI Z88.2, Practices for Respiratory Protection
• [Company Respiratory Protection Program]

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

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