Why RPE fit testing and maintenance matter

Respiratory Protective Equipment (RPE) is a critical layer of defence for workers exposed to airborne hazards – such as dust, fumes and vapours. In this article, senior health and safety HazardCo safety expert Allan Dittmer warns industry that even the best equipment won’t keep you safe if it doesn’t fit properly, isn’t suited to the task, or isn’t well maintained 

Here’s what you need to know about getting RPE right, from upfront fit testing to choosing the right cartridges, to regular check-ups and health monitoring. 

Step 1: Get fit-tested – one size doesn’t fit all 

Before a worker even steps into a hazardous area, they need to be fit tested for the right RPE. Why? Because no two faces are the same. RPE comes in different sizes typically ranging from small to extra large, and a poor fit can mean poor protection, even if the mask looks like it fits. 

To highlight the importance of proper fit testing, we spoke with Registered Nurse Rino Roh from our industry partner Habit Health, whose team supports respiratory protection across a wide range of worksites.  

Roh said, “The right respirator only works if it fits – you wouldn’t wear shoes that don’t fit, so why wear a mask that doesn’t? Fit testing ensures real protection, not just the appearance of safety. What I find most rewarding in my role is knowing that just a few minutes of proper testing can help protect someone’s lungs for a lifetime.” 

Habit Health’s perspective is a powerful reminder that protecting your team’s lungs starts with getting the basics right, and that starts with the right fit. 

Fit testing must be:  

• Conducted before first use of RPE.  

• Repeated at least annually, or whenever the wearer’s face shape changes, due to weight loss/gain, dental work, surgery, or injury.  

• Done with qualitative (using taste or smell) and quantitative (using specialised equipment) methods, and performed by a competent person trained and certified in how to do it. They will be listed in the NZ Occupational Hygiene Society Commit2Fit register.  

Fit testing is also a great opportunity to train workers on how to wear and check their masks properly, which brings us to the next step.  

Step 2: Choose the right RPE for the risk 

Not all filters protect against all hazards. It’s essential to choose RPE that’s targeted to the type of contaminant and the task at hand. 

Here are the main types of RPE 

• Disposable respirators: These can seem handy but don’t offer lasting protection – and yes, even disposable ones need to be fit tested. You’re better off using a reusable option.  

• Reusable half or full-face respirators: These use replaceable cartridges designed for different types of hazards. Full-face respirators also protect your eyes from dust and chemicals.  

• Powered Air Purifying Respirators (PAPRs): These use a battery-powered fan to push clean air through a filter. They’re more comfortable for long wear and great when facial hair makes a tight seal tricky.  

• Supplied air respirators: Used in high-risk environments where there’s little or no oxygen. These systems use compressed air – like what firefighters wear. 

When choosing your RPE, think about:  

• What’s in the air? Dust, gas, mist, or vapour – each needs a different filter. Check the RPE manufacturer’s website or give them a call to confirm the right cartridge.  

• What do the Safety Data Sheets (SDS) say? The SDS for the products you’re using will tell you what type of protection you need.  

• How long and how hard you’ll be working: Longer or more physical jobs may need a more comfortable or powered system.  

• Other gear you’re wearing: Make sure your mask works with your other PPE like glasses, helmets, or earmuffs.  

• Comfort: If it’s uncomfortable, it won’t get worn properly – or at all.  

Need help figuring out what you need?  

If you’re unsure what RPE or cartridges are right for your job, here’s where to start:  

• Find a fit testing specialist: Use the Commit2Fit register to connect with a certified tester. They can assess your work environment and recommend the right type of RPE.  

• Review your site’s risk assessments: If your job involves dust, fumes, or vapours, RPE may be required – make sure this is covered in your hazard documentation.  

• Ask the manufacturer: The RPE manufacturer is the best source for information on which filters or cartridges you need for your work.  

• Talk to HazardCo: Your HazardCo advisor can help you connect with trusted fit testing providers like Habit Health and make sure your team’s RPE setup is fit for purpose.  

Choosing the wrong size or type of RPE can give the illusion of safety while leaving workers dangerously exposed. There’s a big difference between looks safe and is safe. 

Step 3: Maintain the protection over time 

Once the right gear is chosen and correctly fitted, the work doesn’t stop. RPE needs to be maintained, checked, and re-evaluated regularly. 

What ongoing checks are needed? 

Daily visual inspections: Before each use, workers should inspect their RPE for cracks, tears, wear, or contamination. Damaged RPE should not be used. 

Filter and cartridge replacement: There’s no one-size-fits-all rule for changing filters – check with your manufacturer. Never rely on smell or taste to know if filters are still working – by the time you smell something, it is already damaging you. 

Annual fit testing: Our faces change over time. Even subtle shifts in weight or facial structure can impact the mask’s seal. Yearly testing is the recommended standard. 

Proper cleaning and storage: Dirty or improperly stored RPE may not perform when needed. Train workers on cleaning routines and ensure hygienic storage. 

Don’t skip health monitoring 

Even with the best gear, health monitoring plays an essential role in a full respiratory protection programme. It’s how you check whether control measures (like RPE) are really working, and catch signs of harm early. 

Under the Health and Safety at Work Act 2015, you’re required to monitor the health of workers and the conditions of the workplace to prevent injury or illness. Health monitoring can include: 

• Medical exams to ensure workers are fit to wear RPE. 

• Regular checks if there’s long-term exposure to hazardous substances. 

• Investigate if symptoms or health concerns arise. 

Final thoughts: Protecting people, not just ticking boxes 

RPE isn’t just a piece of kit, it’s a commitment to keeping people safe. By following these three steps: 

1. Upfront fit testing. 

1. Choosing the right RPE and cartridges for the job, according to the manufacturers guidance. 

1. Ongoing maintenance and health checks.  

You’re doing more than following regulations. You’re creating a culture where safety is personal, proactive, and properly managed. 

The right mask, worn the right way, backed by the right training and monitoring – that’s how you keep your team safe. 

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HazardCo is a leading health and safety management provider for the construction industry.  

Making it simple for builders and trades to stay compliant and keep their teams safe. For more information,visit www.hazardco.com, email info@hazardco.com, or call 0800 555 339.