User Seal Checks Toolbox Talk

A user seal check is a quick check performed by the wearer every time a tight-fitting respirator is put on. It confirms that the respirator is properly positioned and that the face seal is effective before entering a hazardous work area. A successful fit test does not eliminate the need for a user seal check—both are essential parts of a respiratory protection program.

This toolbox talk reviews the importance of user seal checks and the steps workers should take to verify a proper respirator seal before each use.

Why This Matters

• User seal checks help identify leaks before exposure to airborne hazards.
• A properly sealed respirator provides the intended level of respiratory protection.
• Seal checks help confirm the respirator has been donned correctly.
• Performing a seal check before every use helps prevent hazardous exposures.
• Seal checks are required each time a tight-fitting respirator is worn.

Common Hazards

• Skipping the user seal check before entering a hazardous area.
• Facial hair interfering with the respirator's sealing surface.
• Head straps that are twisted, loose, or improperly adjusted.
• Damaged face seals or respirator components.
• Incorrect respirator size or model.
• Respirator shifting while working.
• Contamination entering through an incomplete face seal.
• Assuming a previous fit test guarantees a proper seal every time.

Safety Checklist

Before Entering the Work Area

• Inspect the respirator for damage, contamination, or worn components.
• Ensure the respirator is the correct model and size for the wearer.
• Adjust the head straps according to the manufacturer's instructions.
• Ensure the face seal is free from facial hair, clothing, jewelry, or other obstructions.
• Perform the manufacturer-recommended positive pressure and/or negative pressure user seal check.
• If the respirator does not seal properly, readjust it or replace it before entering the hazard area.

During Work

• Leave the hazardous area immediately if the respirator becomes loose or loses its seal.
• Do not adjust or remove the respirator while remaining in a contaminated environment unless authorized procedures permit it.
• Replace damaged or defective respirators immediately.
• Report respirator problems to your supervisor.
• Clean, inspect, and properly store reusable respirators after use.
• Never share reusable respirators unless they have been cleaned and disinfected according to company procedures.

Crew Talking Points

• Has everyone performed a user seal check before entering the work area?
• Does anyone have facial hair or another condition that could affect the respirator seal?
• What should you do if your respirator leaks during work?
• Who should be notified if a respirator fails a seal check?
• Why is a user seal check required even after passing a fit test?
• Speak up immediately if you suspect your respirator is not sealing properly.

Stop Work If

• Your respirator cannot achieve or maintain a proper seal.
• The respirator becomes damaged or malfunctions.
• You detect contaminants inside the respirator.
• The respirator shifts or loosens during work.
• You are unsure your respiratory protection is adequate for the hazard.
• You have not completed a user seal check before entering the hazardous area.

Final Reminder

A user seal check is your last opportunity to verify that your respirator is protecting you before exposure begins. Perform a seal check every time you don a tight-fitting respirator, correct any problems immediately, and never enter a hazardous area unless you have confirmed a proper seal.