Silica dust face fit testing guide for small sites

When you run a small demolition or refurbishment job you already know silica dust is a serious health hazard, and the recent HSE Improvement Notice (IN/BBR/MSB/070726/1) shows many firms still miss one vital control – the silica dust face fit testing guide. Without a documented face‑fit test you cannot prove the respirator actually protects the wearer, and you expose yourself to enforcement action. The steps below fit on a typical one‑day site schedule and feed straight into the COSHH risk assessment you already keep on file.

Silica dust face fit testing guide – equipment and paperwork

Select a certified respirator – Use a half‑mask or full‑facepiece that carries an EN 149 certification for silica dust. Check that the mask size matches the wearer’s facial dimensions and that it can be worn with other PPE such as hard hats and safety glasses. A "one‑size‑fits‑most" mask is only acceptable if you are prepared to run a fit test for each worker.

Prepare the record – The HSE does not prescribe a specific template, but the file must show:

• Worker name and date of birth

• Date of test, respirator make/model/size

• Fit factor (quantitative) or a pass/fail note (qualitative)

• Signatures of the tester and the wearer

A free COSHH template can be adapted for this purpose.

Planning the test day on site

1. Allocate time – Reserve at least 15 minutes per employee and slot it into the site induction timetable.

2. Choose a clean area – A low‑dust, well‑ventilated spot reduces the risk of contaminating the test aerosol and gives a reliable qualitative result.

3. Gather tools – You’ll need the respirator, a qualitative fit‑testing kit (saccharin or Bitrex), a mirror, a stopwatch and the record sheet.

4. Brief the worker – Explain why the test matters, demonstrate the mask, and confirm the worker understands the steps. This satisfies the HSE’s competence requirement.

Running a documented face‑fit test

1. Pre‑test inspection

• Look for cracked straps, damaged lenses or a dirty filter.

• Verify the filter rating matches the silica dust protection requirement.

• Ask the worker to perform a quick seal check by inhaling sharply; any leak means the mask must be readjusted.

2. Donning the mask

• Place the mask, tighten straps, and repeat the user seal check.

• Use the mirror to ensure no gaps around the nose bridge, cheeks or chin.

3. Qualitative test (most common for small jobs)

• Follow the kit instructions for the chosen aerosol.

• The worker repeats a series of movements – normal breathing, deep breathing, head turning, talking, and a light exercise such as walking in place – while the aerosol is introduced.

• Detection of taste or smell equals a failed fit; re‑adjust and repeat.

• When the worker reports no taste/smell throughout, record a “pass” and note the test as qualitative.

4. Document the outcome

• Fill in the date, respirator model/size, test type, result and signatures on the record sheet.

• File the record with the site’s COSHH documents and give the worker a copy for their personal PPE file.

Linking the result to your COSHH risk assessment

Your COSHH assessment must show how exposure is being prevented. After a successful face‑fit test, add a line such as:

Respiratory protective equipment – certified half‑mask, fitted and pass‑tested on [date]. Test record filed under COSHH documentation.

If the test fails, note the immediate corrective action – for example, a different mask size, additional training, or the introduction of local exhaust ventilation (LEV). Remember, LEV reduces airborne dust but does not replace the need for a properly fitted respirator.

Quantitative versus qualitative testing – when to upgrade

Most small firms start with a qualitative kit because it is inexpensive and easy to use. However, if you work on projects with very high dust concentrations, a quantitative fit test (using a PortaCount or equivalent) provides a numeric fit factor and greater confidence in protection. Quantitative testing is also useful when you need to demonstrate compliance to a client or insurer. The cost difference is offset by reduced re‑testing and fewer fit‑fail incidents.

Maintaining respirators and re‑testing triggers

• Routine checks – Inspect masks and filters at the start of each shift. Replace filters according to the manufacturer’s schedule or when you notice a pressure drop.

• When to re‑test – New employee, change of mask model, facial hair growth, weight change of more than 5 kg, or a shift in work type (e.g., from plaster demolition to concrete drilling) all merit a fresh test.

• Record‑keeping – Store electronic copies on a site drive or within your compliance software. The Site Book can generate a RAMS document that pulls the fit‑test outcome automatically, helping you stay audit‑ready.

Simple audit checklist for site supervisors

• Competent person identified and trained

• Certified respirator selected and available

• Clean test area earmarked

• Fit‑test records filed with COSHH assessment

• Re‑test trigger list reviewed weekly

Common pitfalls and how to avoid them

• Skipping the user seal check – Unnoticed leaks let dust bypass the filter. Remedy: Always perform the inhalation/exhalation check before the aerosol test.

• Using an ill‑fitting mask – Repeated failures, lost productivity. Remedy: Keep a range of sizes on site; fit each worker before testing.

• Failing to record the test – No evidence of compliance if inspected. Remedy: Use the simple template linked above and file it with the COSHH record.

• Assuming a "pass" lasts forever – Facial changes or mask wear can degrade fit. Remedy: Re‑test whenever any trigger listed in the audit checklist occurs.

Next steps for your small site

1. Review your current COSHH assessment and locate the section on respiratory protection.

2. Order a certified silica‑dust respirator kit that includes a qualitative test kit.

3. Schedule a brief training session for the staff member who will run the tests.

4. Run the silica dust face fit testing guide on your next job and attach the records to the COSHH risk assessment.

5. Keep the records in the Site Book or your preferred compliance system so they are ready for any HSE check.

By embedding the fit‑test workflow into your everyday paperwork, you turn a regulatory requirement into a routine safety habit – and you protect your crew from silicosis.

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