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RR1222: Face Fit testing of FFP3 respirators: the impact of sampling port location

Practice to the Control of Substances Hazardous to Health (COSHH) Regulations 2002 (as amended) states that, if respiratory protective equipment (RPE) is required, any tight-fitting respirators used should be face-fit tested using a suitable method, by a competent person.

Suitable methods for fit testing of tight-fitting RPE check that a specific model and size of respirator seals adequately to the wearer’s face with no gaps through which airborne hazardous substances can enter.

The study objectives were to determine if there was a difference in fit factors and in the within-wearer variability between the flush (flush with the inside surface of the respirator) and extended (extended into the wearer’s breathing zone) ports used in fit testing, for filtering facepiece class 3 (FFP3) respirators.

Fit testing research was carried out with human volunteers on a variety of FFP3 respirators using both flush and extended ports.

The results provide an evidence base for why an extended port should be used in fit testing.

The study provides evidence that the repeatability of the fit test did not differ by port location and that effective fit testing can be carried out using an extended port.

Visit the RR1222 report (PDF) [1]

This report and the work it describes were funded by the Health and Safety Executive. Its contents, including any opinions and/or conclusions expressed, are those of the authors alone and do not necessarily reflect HSE policy.

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Updated 2025-04-03