WHAT TO EXPECT DURING YOUR MASK FIT TEST
- Rebekah McCutcheon
- Feb 4
- 6 min read
Updated: Feb 26
If you've been told you need a mask fit test - whether for work, a clinical placement, or a new job site - you might be wondering what actually happens on the day. This article walks you through exactly what to expect when you book with Fit Test Australia, from arrival through to your certificate.
Why Do You Need a Mask Fit Test?
Anyone required to wear a tight-fitting respirator needs to have it properly fit tested. A respirator only works if it seals correctly to your face - if it leaks, you're still being exposed to the very hazard the mask is supposed to protect you from.
The AS/NZS 1715:2009 standard requires that all tight-fitting respirators be fit tested before first use and annually after that. It's not just best practice - for most industries in Australia, it's a legal requirement.
Not all faces are the same, and not every mask fits every person. The fit test determines which brand, model, and size of respirator actually seals to your unique face shape. Without it, you're guessing.
Before Your Appointment - What You Need to Know
A few things need to be in place before we can test you. These requirements come directly from AS/NZS 1715:2009 - they're not just FTA policy.
Be clean shaven in the mask seal zone - no stubble, beard, or goatee where the mask makes contact with your face. Even a small amount of facial hair breaks the seal and will cause a fail. If you have a beard, ask us about PAPR options for facial hair.
No smoking, vaping, or eating within 30 minutes of your test. Food and smoke particles alter the particle count and can cause false readings. Water is fine.
Bring your PPE - if you've been issued a specific mask at work, bring it. We test the mask you'll actually be wearing on the job. If you don't have one yet, we can assist you on the day.
What Happens on the Day
When you arrive, our team will confirm your prerequisites have been met, enter your details into our software, and walk you through everything before the test begins. Here's the order of what happens:
Step 1 - Training
Before we start the test, we cover the basics with you. This includes:
How to correctly put on and take off your respirator (donning and doffing)
How to perform a mask seal check (fit check) every time you wear it
What the fit test involves and what we're measuring
The purpose of your specific respirator and what hazards it protects against
Step 2 - Donning the Mask
We help you put the mask on correctly and check that it's positioned properly and that a seal is being achieved before we insert the test probe. For disposable masks (N95, P2), this means nose piece moulded to your face and straps positioned correctly. For reusable elastomeric masks, we check the harness is sitting right.
Step 3 - The Fit Test
We use a TSI PortaCount 8048 - the gold standard for quantitative fit testing in Australia. A small probe is placed inside your mask and connected to the machine via tubing. The PortaCount measures the particle concentration outside your mask and inside it at the same time, calculating a numerical "fit factor" score. A minimum fit factor of 100 is required to pass.
Using the OSHA modified quick exercise protocol, we challenge the seal by asking you to move through a set of natural exercises. If a mask can't hold its seal during normal movement, it won't protect you on the job.
The exercises are:
Bending at the waist
Reading the rainbow passage (or jogging in place if you're testing a reusable elastomeric mask)
Looking side to side
Looking up and down
You'll be asked not to touch or adjust the mask during the test. If you do, the test may need to be stopped and restarted. Just move naturally and breathe normally.
If you're testing a reusable elastomeric mask, we'll also run through cleaning, storage, and filter replacement with you at this point. Using the wrong filter for your hazard means the mask still won't protect you, so this is an important part of the appointment.
What Happens if You Fail?
A fail isn't the end of the appointment - it's actually useful information. If the mask you've brought doesn't pass, we'll test alternative brands, models, or sizes until we find one that does. Most people leave with a passing result, just sometimes in a different mask to the one they arrived with.
Common reasons for a fail include the wrong size, a model that doesn't suit your face shape, or an issue with donning technique that's easy to fix. We'll work through it with you.
If a seal absolutely cannot be achieved with a tight-fitting respirator - for example, due to facial features that affect the seal zone - we'll talk through alternatives including powered air purifying respirators (PAPRs), which don't require a facial seal at all.
Your Certificate and ID Card
Once you've passed, we issue your fit test certificate on the spot and email it to you immediately. We also print you a pocket-sized ID card showing your name, the mask you were tested on, and your result. This is particularly handy on construction sites or in healthcare facilities where compliance may be checked.
The whole appointment takes around 10-15 minutes if all goes smoothly. If we need to test multiple masks, allow a little extra time.
How Often Do You Need to Be Fit Tested?
Under AS/NZS 1715:2009, fit testing must be done before first use and at least annually after that. You'll also need to retest if any of the following occur:
You're issued a different brand, model, or size of respirator
Significant weight loss or gain (which changes your face shape)
Major dental work, facial surgery, fillers, or trauma to the face
A broken nose or other changes to the nose structure
Frequently Asked Questions
Is a mask seal check the same as a fit test?
No. A mask seal check is a quick self-check you do each time you put on your mask. A fit test is a formal, validated assessment that determines whether a specific mask is the right size and model for your face. Both are required - they serve different purposes.
Do I need to bring my own mask?
If you've been supplied a specific mask at work, yes - bring it. We test the mask you'll actually be wearing. If you don't have one yet, let us know when you book and we can advise you or supply options on the day.
Can I be tested if I have a beard?
Not with a tight-fitting respirator - facial hair in the seal zone will cause a fail every time. You would either need to shave, or we can discuss loose-fitting alternatives like a PAPR that don't require a facial seal.
What does a quantitative fit test actually measure?
The PortaCount 8048 simultaneously measures the concentration of particles in the air around you and inside your mask. The ratio between the two gives a numerical fit factor. A score of 100 or above means the mask is filtering out at least 99% of airborne particles at the seal - which is the minimum required to pass. Read more about quantitative vs qualitative fit testing here.
Where can I book?
We have clinics in Randwick (Sydney), Fairfield (Sydney), Toorak (Melbourne), Moonee Ponds (Melbourne), and Leederville (Perth). We also offer mobile fit testing at your workplace - contact us to arrange.
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