The COVID-19 pandemic has led to a surge in face mask demand, resulting in increased face mask waste and environmental impacts. This study investigates mask usage patterns and the environmental impacts of single-use and cloth masks across three phases: pre-COVID-19, COVID-19, and the new normal. A comprehensive survey conducted in five cities across four Asian countries reveals a surge in mask usage during COVID-19 (6.81 pieces/week), followed by a decline in the new normal (3.73 pieces/week), though usage remained higher than pre-COVID-19 levels (1.46 pieces/week). For single-use masks, age significantly impacts usage in all cities, while gender and education level affect usage in Shanghai, Harbin, and Depok. Household income influences mask use in Shanghai and Harbin. For cloth masks, education level significantly correlates with usage in most cities. The study highlights the significant environmental impact of mask use, particularly in densely populated urban areas. Switching to cloth masks for one year could reduce carbon footprints by 44.27–81.9 million kgCO2eq, decrease solid waste by 34.81–52.41 million kg, and reduce microplastic emissions by 6.50 to 15.56 trillion particles in the first 24 h after disposal. However, this transition may increase water usage by 1.73–1.86 billion m3H2Oeq. The study also offers policy recommendations on mask usage and disposal.