Purpose of a Respirator Fit Test

A fit test confirms that a specific respirator model can form an adequate seal on an individual’s face, preventing harmful particles from bypassing the filter. When a leak occurs, contaminants can enter the breathing zone regardless of the respirator’s filtration rating, making the protection ineffective.

OSHA recognizes two categories of fit testing:

Quantitative Fit Testing (QNFT)

• Measures actual leakage using instruments such as the TSI PortaCount.

• Generates a numerical fit factor indicating seal performance.

• Appropriate for N95 filtering facepiece respirators, half-mask elastomeric respirators, and full-face respirators.

Qualitative Fit Testing (QLFT)

• Uses aerosolized agents with a distinct taste or odor (e.g., saccharin or Bitrex).

• Determines pass/fail based only on whether the agent can be detected by the user.

• Acceptable only for certain applications and minimum protection factors.

Many employers choose quantitative fit testing because it is more accurate, defensible, and applicable to a broader range of respirators.

OSHA Requirements: When Fit Testing Must Occur

OSHA requires a fit test to be completed:

• Before an employee uses a tight-fitting respirator for the first time.

• Before using a new brand, model, size, or style of respirator.

• At least annually (once every 12 months).

• Whenever a physical condition could affect the seal, including:

  • Significant weight change.

  • Major dental or facial surgery.

  • Scarring or traumatic changes near the seal area.

  • Facial hair growth that interferes with the seal.

• Whenever the employee reports difficulty achieving or maintaining a seal during use.

These requirements apply broadly across industries, including construction, healthcare, manufacturing, and environmental operations.

Medical Clearance Requirements Before Fit Testing

OSHA requires employees to obtain medical clearance before they can be fit tested or use a respirator in the workplace. Typically, this involves the completion of the confidential medical questionnaire found in Appendix C of the standard, reviewed by a licensed healthcare professional. Additional evaluation, such as pulmonary function testing, may be required at the healthcare provider’s discretion.

Medical clearance must be completed before fit testing is scheduled.

Length of a Fit Test

A quantitative respirator fit test typically requires approximately ten minutes per person per respirator model. The full process may involve additional time for medical clearance review, respirator selection, donning instruction, and recordkeeping. When performed on-site, employers can schedule testing in half-day or full-day blocks to minimize disruption to operations.

Industries Where Fit Testing Is Common

Fit testing is required wherever tight-fitting respirators are used to protect against airborne hazards. Common examples include:

• Exposure to crystalline silica, asbestos, or metals during construction or demolition.

• Infectious disease control in healthcare and long-term care facilities.

• Chemical exposure in industrial manufacturing and fabrication.

• Aerosol or particulate hazards during environmental remediation.

• Chemical, particulate, or pathogen exposure in laboratories, utilities, or emergency response.

If a tight-fitting respirator is required to protect against workplace contaminants, fit testing is also required.

On-Site Fit Testing in the Southeast

Many organizations choose on-site fit testing to avoid travel time, minimize downtime, and support all work shifts. On-site services allow employees to complete required testing while maintaining operational efficiency.

Georgia Fit Testing provides quantitative respirator fit testing using TSI PortaCount instruments, assistance with medical clearance coordination, and respirator program guidance. Service coverage extends within 250 miles of Atlanta, including Georgia, Alabama, Tennessee, South Carolina, and North Carolina.