OSHA's New Quantitative Fit-Testing Protocols Aim to Save Time & Effort
iSi conducts both quantitative and qualitative fit-testing and can help you determine what your facility's needs are for respiratory protection.
OSHA has added two new fit testing protocols for quantitative respirator fit-testing.
⚡ TL;DR: OSHA’s updated quantitative fit-testing protocols cut test time by approximately 5 minutes per respirator by eliminating 4 of 8 exercises (grimace, normal breathing, deep breathing, and one other) that rarely affected fit factor. Qualitative fit testing is limited to half-mask and N95 respirators with APF ≤10. Any respirator with APF >10 (including full-facepiece respirators with APF 50) requires quantitative testing. PortaCount models 8030, 8038, 8040, and 8048 need software updates; older models are limited to original protocols. The two new protocols are actually modifications of the current ambient aerosol CNC protocols for full-facepiece, half-mask elastomeric, and filtering facepiece respirators. These modifications cut in half the number of steps required, also making them faster to conduct.
There are two types of manufacturers of quantitative fit-testing machines which are most popular, the Portacount by TSI and a controlled negative pressure (CNP) machine by Occupational Health Dynamics, or OHD. The changes in the protocols affect TSI’s PortaCount-type machines.
Quantitative Fit Testing vs. Qualitative Fit Testing
Qualitative fit-testing uses items such as saccharine or irritant smoke to determine protection. It relies on the person being tested’s ability to sense odor or irritants. Qualitative fit testing is only for half-face and N95 filtering facepiece respirators that have an APF of 10.
⚠️ Why this matters: Respiratory protection programs are a top OSHA citation generator. Most facilities fail because they: don’t fit-test annually, don’t maintain fit-test records, don’t provide medical clearance exams, or don’t store respirators properly between uses. If an employee is exposed to airborne hazards without a compliant respiratory program backing the PPE, you’re liable for serious violations at $16,550+ each.
Quantitative respirator fit-testing uses a machine to measure pressure loss inside the mask or to count quantities of particles to calculate a fit factor. Quantitative testing is considered more accurate than qualitative fit-testing. Quantitative fit-testing must be conducted for respirators requiring an Assigned Protection Factor (APF) over 10. Full-face tight fitting respirators have an APF of 50 and thus need to be quantitatively fit-tested.
The New Protocols
OSHA based their new protocols on the results of three different studies. After consideration and comment, 4 of the 8 exercises were removed or changed. These include the grimace exercise, normal breathing, and deep breathing. The grimace exercise was often found to shift the fit of the mask while the breathing exercises were considered exercises that rarely affected fit factor.
For full facepiece and half-mask respirators, talking was eliminated in favor of jogging-in-place, a new exercise. Additional changes were made to the number of sets and the duration.
OSHA anticipates 5 minutes can be shaved from each fit-test with the new protocols.
PortaCount Upgrades Needed
If you have PortaCount Models 8030, 8038, 8040 or 8048, you will need a software upgrade that you can download from the TSI website. You can also have the update uploaded when you send in your machine for its annual service.
PortaCount Model 8020 or 8028 users will only be able to use the original 8-step protocols.
If you have a machine manufactured by another company which uses the same protocols, you will need to check with your manufacturer if the machine you’re using requires an update.
Link to the New Protocols
For more information about the specific protocols, visit the revised Appendix A of the standard.
The time savings from the updated protocols means you can fit-test more frequently without proportional cost increases. Since fit factor changes with weight loss, facial hair growth, or scar tissue development, staying current with testing is critical for worker protection.
Most facilities skip annual fit testing because of cost or time constraints. The streamlined protocols make compliance easier, but they don’t eliminate the requirement for baseline medical exams, training, cartridge replacement schedules, or proper storage.
💰 What respiratory protection citations cost: A manufacturing facility with 20 workers in dusty areas that lack fit-test records and recent medical exams faces $16,550+ per worker exposure = $321,000+ in violations. Establishing a proper program costs $3,000–$6,000.
Frequently Asked Questions
Q: What is the difference between quantitative and qualitative respirator fit-testing?
A: Quantitative fit-testing uses instruments to measure particle counts or pressure loss and is more accurate. Qualitative fit-testing relies on the wearer’s sensory perception (smell or irritant sensation) and is only approved for half-mask and N95 filtering facepiece respirators with an Assigned Protection Factor (APF) of 10 or less.
Q: Which respirators require quantitative fit-testing?
A: Any respirator with an Assigned Protection Factor (APF) greater than 10 requires quantitative fit-testing. Full-facepiece tight-fitting respirators have an APF of 50 and must be quantitatively fit-tested. Half-mask elastomeric respirators also typically require quantitative testing under 29 CFR 1910.134 (Respiratory Protection).
Q: How did OSHA’s new quantitative fit-testing protocols reduce testing time?
A: OSHA updated the protocols based on research showing that certain breathing exercises (normal breathing, deep breathing) and the grimace exercise rarely affected fit factor results. By removing 4 of 8 original exercises and replacing some with more efficient tests like jogging-in-place, the new protocols reduce testing time by approximately 5 minutes per respirator.
Q: Do all PortaCount machines support the new fit-testing protocols?
A: PortaCount Models 8030, 8038, 8040, and 8048 require a software upgrade available from TSI to use the new protocols, while Models 8020 and 8028 are limited to the original 8-step protocols. Facilities should check with their equipment manufacturer to determine if software or hardware updates are needed for compliance.
We Plug In. You Level Up.
Need respiratory protection program support? Contact iSi Environmental for a same-day quote, or explore our osha services to see how we can help your facility.