Top 10 Myths and Mistakes About Respiratory Protection and Fit Testing
- Crystal Polson
- 19 hours ago
- 7 min read
When it comes to respirators and fit testing, there’s no shortage of misinformation and bad advice floating around worksites and on social media.
Here are the top 10 myths and mistakes we see most often — and how you can fix or avoid them.
1. Mistake: Buying Size Large Masks for Everyone
This is a big one (pun intended). We often see employers purchasing reusable respirators, in size large, for every employee.
Respirators aren’t one-size-fits-all. Even within the same brand, the shape, nose bridge, and seal can differ. Buying only size large is like handing out one shoe size to an entire workforce. Just don't do it.
How to Avoid:
Don't buy all your masks in size large.
At Fit Test Victoria, we provide a wide variety of respirators in different brands, models an sizes. We can fit test you - or your staff - and then let you know which mask fits best. We try to stick to the same brand/model when possible.
If you are purchasing respirators from your supplier, be sure to get a variety of sizes. And buyer beware - there are some masks that just don't pass a fit test...ever. We can advise you on which ones to avoid.
Mistake: Getting Fit Tested in One Brand/Model/Size Mask and Then Wearing a Different Mask
The purpose of a fit test is to identify the exact brand/model/size respirator that fits your face. All too often, we see people getting fit-tested in one mask and then wearing a completely different one at work.
If you pass a fit test with a Maxiguard 7500 half-face respirator in size medium, that's the respirator you should use. Even if you changed from medium to small in that mask, the small size still needs to be fit-tested.
Same goes for disposable N95/P2 masks. You wear the exact brand/model/size you pass a fit test in. For example, if you pass a fit test in a Trident P2 in size regular, you can't then wear a 3M 9322A mask.
How to Avoid:
This is an easy one. Always wear the exact brand/model/size respirator that you pass a fit test in.
Mistake: Buying the Cheapest Mask
In Australia, respiratory protective equipment (RPE) is certified under the AS/NZS 1716:2012. We also use NIOSH-certified RPE (NIOSH is the U.S. body).
Even though you may be doing the right thing and purchasing 1716 or NIOSH-certified masks and filters, this doesn't mean they will be a good fit.
What we've learned over the years is that buying the cheapest respirators usually means they won't pass a fit test. In fact, we've fit tested some brands/models of respirators that NEVER pass a fit test. Never. And it's usually the cheaper ones that fail.
There are manufacturers producing knock-offs of quality brands at cheaper prices, and the knock-offs just don't fit as well as the OGs.
This doesn't mean you can't buy excellent quality RPE at a reasonable price. You absolutely can. We just want you to be aware that you get what you pay for.
How to Avoid:
If you know the type of mask you need for your workplace or job and haven't purchased one yet, give us a call. Let us know which brand/model you're considering, and we'll share our feedback on the fit.
If you already have masks and are unsure if they fit, we'll do what we do best and fit test them for you. If they fail, we can use masks from our supply and will test until we find a fit.
Myth: Any Full Face Respirator Can Be Worn with Facial Hair
We hear this one a lot. People think that any full-face respirator can be worn with facial hair.
Respirators that rely on a tight seal for protection require a clean shave and must be fit-tested. This is true for half face, full face and disposable masks.
Fix It:
The option for people with whiskers is a powered-air purifying respirator (PAPR) with a loose-fitting hood or helmet. A few examples are in the photo below. Facial hair should be neatly trimmed. Bushy beards can decrease the effectiveness of the PAPR. Loose-fitting headpieces do not require fit testing.
Some PAPRs are worn with tight-fitting facepieces. These cannot be worn with facial hair and require fit testing.
Myth: Fit Testing is Optional - a 'nice to have'
Under the OHS Regulations 2017 (Vic) and equivalent laws across Australia, employers must ensure that PPE is suitable and properly fitted to each worker. Fit testing is the only way to assess respirator fit.
State and territory regulators all note that fit testing is a requirement. A few excerpts:
The AS/NZS 1715:2009 also notes that fit testing is a requirement for all tight-fitting respirators and being clean shaven is a must.
Fix it:
If you're using tight-fitting respirators, but sure to book in fit testing when the respirator is first issued and annually thereafter.
Mistakes: Not knowing which filters to use, when to change them and where to get them
It's not unusual for us to come across folks who are dutifully using their respirators, but the filters are entirely unsuitable for the hazard.
For example, we see environments where the airborne contaminant is silica dust, but the filters being used are for gases/vapours only. Or vice versa - the hazard is chemicals and particulate-only filters are being used.
Unfortunately, we encounter a lack of knowledge around when to change filters. And some workers don't even know where to get replacement filters when they do need to be changed.
Fix it:
The best thing you can do is to have a written respiratory protection program in place in line with the AS/NZS 1715:2009.
It is vitally important to conduct a risk assessment to identify the harmful contaminants in your workplace, determine the type of RPE and filters needed, and know when those filters need to be changed. Employers should always have replacement filters readily available when staff need to change their filters.
In some cases, it may be necessary to engage with an occupational health and safety professional - such as an occupational hygienest - who is well versed in RPE selection to help.
Myth: We don’t need a written Respiratory Protection Program — fit testing alone is fine.
This is a major misconception. Fit testing is just one component of a proper respiratory protection program. Without policies and procedures in place for selection, maintenance, training, and review, you’re missing the framework that makes compliance sustainable.
The components of a respiratory protection programs include:
-Appointing a program administrator
-Risk assesssment
-RPE selection, care, maintenance, storage
-Fit testing
-Training
-Record keeping
-Program evaluation
Medical assessments may also be necessary if you have staff who may not be able to wear RPE safely due to medical or psychological conditions.
Fix it:
If you don't have a copy of the AS/NZS 1715:2009, get one!
Develop a written respiratory protection program, update it regularly and make sure all relevant stakeholders are awere it exists (and how to apply/implement it).
Mistake: Using Compressed Air to Clean Filters
Please don’t. That’s a fast way to destroy your filters and reduce protection. Blasting compressed air through a filter can damage the fibres and electrostatic charge that make it effective.
You might think you’re cleaning it, but you’re actually blowing holes in its filtering media and dispersing harmful contaminants in the air around you.
Fix it:
Easy. Just don't do it.
Mistake: Not Taking Care of Your Respirator.
We've seen many respirators in a sad state, to say the least. Cracked facepieces, overstretched headstraps, duct tape covering the area where a filter should be, years' worth of dirt and grime, filters that have never been changed.
Reusable respirators need routine cleaning and should be stored in a clean, dry place away from heat, sunlight, and contaminants.
Fix it:
Clean your respirator after every shift. If it's not overly dirty, you can use an alcohol wipe. If it needs a more thorough clean, refer to the manufacturer's instructions. Most reusable respirators can be washed using warm water and a neutral detergent. Do not wash filters.
Cleaning is a good time to inspect your respirator for any damage or wear. Also check that all the bits and pieces - such as valve covers - are in place.
After cleaning and air-drying, store your mask and filters in a clean, dry place out of the heat and sunlight. Using a plastic tub or container is a good idea (and many respirator kits come with a storage container).
10. Myth: I don't really need to be clean-shaven to wear my mask (do I?)
We hate to break it to you. But yes, you do need to be clean shaven anytime you wear a tight-fitting respirator, including during a fit test.
To provide their intended level of protection, respirators with a tight-fitting face seal require a smooth surface to seal correctly. Even stubble can compromise the fit.
The AS/NZS 1715 clearly outlines this requirement, as do all the manufacturers' instructions for tight-fitting respirators. This is true for reusable masks and disposable N95/P2 masks.
And no, you can't put vaseline on your beard to improve the seal. We've even heard Work Safe regulators making this recommendation!
A client recently asked us if he could use didgeridoo wax. It was very tongue-in-cheek but gave us a good chuckle.
The only option for people with facial hair is loose-fitting PAPRs.
Fix it:
Employers — make your facial hair policy clear before hiring. We recently noticed that one company stated in its Seek job ad that being clean-shaven is mandatory because tight-fitting respirators are worn. This is a smart move that sets expectations from day one.
And if you're the one wearing a tight-fitting respirator, you must understand that if you have facial hair, you are putting your health at risk.
That's a Wrap
Respiratory protection shouldn't be about ticking boxes — it’s about protecting people’s health.
You can avoid the mistakes outlined in this article by ensuring you fully understand your workplace hazards, implementing a proper respiratory protection program, using the right RPE and filters, getting fit tested, and asking for help when you need it.
Remember - "I didn't know" isn't an excuse.
If you need help implementing a respiratory protection program, need mask or earplug fit testing, or just have questions, get in touch with us at Fit Test Victoria. We have offices in Moonee Ponds, Oakleigh and Geelong. And we provide onsite services Australia-wide.
0428 630 109
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