Developing an OSHA Compliant

Respirator Program

Stan Liang, CIH, CSP, CET

KTA-Tator, Inc.
 Respiratory Protection Webinar
Objectives
 Brief overview of the
following:
 Procedures for implementation of respiratory
protection
 Requirements of the OSHA Respiratory
Protection Standard
 Elements of a written respiratory protection
program

 Resources for additional

information
 Respiratory Protection
• Last line of defense in protecting employees from
harmful dusts, mists, gases and vapors
• Feasible engineering controls or work practice
must be implemented before the use of respiratory
protection can be considered
• Job rotation not permitted by some OSHA
standards
Engineering Controls
• Vacuum shrouded power
tools
• Ventilation
• Wet surface preparation
methods
• Substitution
 Respiratory Protection
• Must be selected in accordance with procedures
established in the respiratory protection program
• Must be fitted, used, and maintained properly
• Must be provided at no cost to the employee
 Maximum Use Concentration
(MUC)
• Key consideration in the selection of respiratory
protection
• Determined by multiplying the respirator’s
Assigned Protection Factor (APF) times the
Permissible Exposure Limit (PEL)
• Level of airborne hazards should not exceed the
MUC
 Respirator Classification
• Air-purifying respirators
• Air-supplied respirators
 Air-Purifying Respirators

Uses mechanical filters or chemical cartridges to

remove contaminants from the air that workers
breathe
Half Face APR
• Assigned Protection
Factor of 10
• Can not be used if
respiratory hazards can
cause eye irritation
Full Face APR
• Assigned Protection
Factor of 10 or 50
• Protection factor depends
on fit test method
Powered Air Purifying Respirator
• Uses battery operated
blower
• APF ranges from 25 to
1000
• Loose fitting hood or
helmet type may be
assigned to workers
unable to wear tight fitting
air purifying respirators
 Filter Selection for Toxic Metals
• HEPA cartridges must be used for toxic metal
hazards
• HEPA cartridges designated as N100, R100, or
P100
 Filter Selection for
Painting Operations
• Organic vapor (black) cartridges for roller/brush
application
• Organic vapor (black) cartridges with mist pre-
filter for spray painting
 Air-Purifying Respirator and PAPR
Limitations
• Can not be used in conditions considered
immediately dangerous to life and health
• Can not be used where oxygen concentrations are
below 19.5%
• Can not be used if concentration of respiratory
hazards exceed the protection factor of the
respirator
 Air-Purifying Respirator and PAPR
Limitations
• Cartridges have a limited service life
• Cartridges have a limited shelf life
• Personnel who have severe scarring or other
conditions which prevent the mask from sealing
to the face may not use tight fitting air-purifying
respirators
 Air-Supplied Respirators

Provides the wearer with a continuous supply

of clean, breathable air delivered to a tight-
fitting facepiece or loose-fitting hood
Supplied Air Respiratory Protection
• Assigned Protection
Factor up to 10,000
(depending on the type of
respirator)
• Tight fitting full face air
line with auxilliary SCBA
can be used in confined
spaces with IDLH
atmospheres
 Air-Supplied Respirator
Limitations
• Length of air line must not exceed 300 feet
• Line may kink, be cut, or be entangled
• Line may become contaminated
 Air-Supplied Respirator
Limitations
• Use only air line, vortex, and other equipment
specified by the manufacturer
• Pressurize the air line in accordance with
manufacturer specifications
• Air line couplings must be compatible with
breathing air systems only
 Air-Supplied Respirator
Limitations
• The compressed air bottle for the escape SCBA
must be hydrostatically tested in the following
intervals:
– Every 3 years - aluminum wrapped with fiber glass
– Every 5 years - steel
• Supplier of breathing air must certify in writing
that breathing air is Grade D quality
 Air-Supplied Respirator
Limitations
• Grade D requirements:
– 19.5% to 23.5% oxygen
– Less than 10 ppm CO
– Less than 1,000 ppm CO2
– Less than 5 mg/m3 hydrocarbons
• Do not use pure oxygen as breathing air
 Air-Supplied Respirator
Limitations
• Portable or self contained compressed air
cylinders used as breathing air sources last from
30 minutes to 60 minutes
• Escape SCBAs usually provide 5 minutes of air
• A low pressure alarm must be provided (if using a
breathing air cylinder)
 Abrasive Blasting Respirators
Type CE
• Required for abrasive
blasting
• Check with manufacturer if
using for other applications
• Provides a protection factor
of 1,000 (selected makes and
models) or 25
• Not for immediately
dangerous to life and health
atmospheres
 Inspection of Respiratory Protection
• Respirators must be inspected before and after use
 Inspection of Respiratory Protection
• Inspect facepieces for:
– Excessive dirt or contamination
– Cracks, tears or holes
– Cracked, scratched, or improperly mounted facepieces
(on full facepiece masks)
– Cracked or broken air purifying element holders
– Damaged threads/gaskets
 Inspection of Respiratory Protection
• Inspect headstraps or head harness for:
– Broken straps or headbands
– Loss of elasticity
– Broken or malfunctioning buckles and attachments
 Inspection of Respiratory Protection
• Inspect facepiece interior for:
– Foreign material
– Cracks, tears, or distortion in valve material
– Cracks, breaks, or chips in the valve body, particularly
at the sealing surfaces
– Missing or defective valve covers
– Improper installation of valve bodies
 Inspection of Respiratory Protection
• Inspect air-purifying elements for:
– Incorrect cartridges/pre-filters
– Loose connections/cross threading
– Expired cartridge shelf life date
– Cracks/dents on cartridge
– Evidence of prior use
 Inspection of Respiratory Protection
• Inspect breathing tube (if air line used) for:
– Broken or missing gaskets or O-rings
– Missing or loose hose clamps
– Deterioration found by stretching hose and looking for
cracks and tears
 Inspection of Respiratory Protection
• Inspection of air line systems for:
– Bottle on escape pack fully recharged
– Cylinder for supplying breathing air fully charged
– Breathing air in cylinder (if used) certified as Grade D
– Pressure in air line as specified by manufacturer
– Low pressure alarm functional
 Donning Respiratory Protection
• Once the respirator is donned, the wearer should
check that the mask is properly placed on the face
and the straps are properly tightened
• The positive or negative pressure check must be
performed each time the respirator is donned
Negative Pressure Seal Check
Positive Pressure Seal Check
 Procedures for Use of
Respiratory Protection
• Users of tight-fitting masks must not have facial
hair that interferes with facepiece seal
• Contact lenses may be worn with respiratory
protection
• Other PPE worn with respiratory protection can
not interfere with the seal of tight fitting
respirators
 Procedures for Use of
Respiratory Protection
• Respirator users shall leave the work area when:
– Workers need to wash their face and respirators to
prevent skin irritation
– Vapor or gas breakthrough is detected
– Filters require replacement
 Cleaning Respiratory
Protection
• Wipe interior/exterior of respirator with
manufacturer approved towelette at the end of the
shift
• Use mandatory OSHA procedures when:
– Respirator is heavily contaminated
– Respirator is used by another person
Respirator Storage
• What is a good practice in
this picture?
• What mistakes are shown
here?
 Respirator Storage
• Do not store respirators in areas where they are
exposed to the following:
– Contamination
– Direct sunlight
– Dust
– Extreme temperatures
– Must be packed or stored to prevent deformation
 Repairing Respiratory Protection
• Remove defective respirators from service
• Make repairs in accordance with manufacturer
recommendations
• Use only manufacturer approved parts
 Medical Evaluations
• Medical evaluations must be provided to wearers of
respiratory protection before fit testing or use
• Employees who refuse an evaluation can not be assigned
to tasks where respirators are required
• Provided by a physician or healthcare professional (within
the scope of their license)
• Evaluations are conducted by having the employee
complete the questionnaire in Appendix C of the standard
 Medical Evaluations
• Questionnaire must be administered in a time and
place convenient to the employee
• Translation of the questionnaire is required for
non english speakers
• Employees have an opportunity to discuss the
questionnaire and results with healthcare
professional
 Medical Evaluations
• The employee must be provided with a copy of
the medical determination
• Information collected via questionnaires is kept
strictly confidential
 Medical Evaluations
• The medical determinations include the following
information:
– Limitations on respirator use
– Medical fitness
– Need for follow-up evaluations
 Medical Evaluations
Evaluations (in addition to initial evaluation) provided if:
•Employee reports signs or symptoms related to the ability
to use a respirator
•Health care professional or Respirator Program
Administrator determines that the employee needs to be
evaluated
•Information from fit testing or program evaluation
indicates the need for another evaluation
•Changes in workplace conditions result in increased
physical stress on the employee
 Fit Testing
• Required annually for all tight fitting respirators
• Must be performed for each make, model, and size
worn
• Another fit test is needed for a change in weight or
other medical condition which could change
respirator fit
• Workers must be clean shaven and medically
approved to be fit tested
Qualitative Fit Testing
• Must be performed in
accordance with
Appendix A
• Several options permitted
by OSHA
Quantitative Fit Testing
• Required only for full
face air purifying
respirators
• Must be performed
following procedures in
Appendix A
 Elements of a Respiratory
Protection Program
• Designation of a Respirator Program
Administrator
• Procedures for selecting respirators (hazard
evaluation required)
• Medical evaluations
• Procedures for proper use (including written
change schedules for gas/vapor cartridges)
 Elements of a Respiratory
Protection Program
• Procedures and schedules for cleaning,
disinfecting, storing, repairing, and maintaining
respirators
• Procedures for evaluating the effectiveness of the
program
 Training Program Requirements
• Required annually or if there are changes in the work
place, evidence that training is not effective, or other
indication that retraining is needed
• Training topics include why respirator use is required,
proper procedures for use, limitations of respirators,
and requirements of the standard.
• Hands on training, information in manufacturer
manuals, and documentation of training is
recommended
 Elements of a Respiratory
Protection Program
• Atmosphere must be classified as IDLH under the
following conditions:
– oxygen level less than 19.5%
– concentrations of toxic gases above IDLH
concentrations
– hazard evaluation is not performed
 Elements of a Respiratory
Protection Program
• Procedures for IDLH atmospheres include the
following:
– use SCBA or combination SCBA/air line respirators
– workers stationed outside the work area for emergency
response
– employer must be notified before start of rescue
operations and be able to provide necessary assistance
 Voluntary Respirator Use

• Respirators may be provided to the employee

where use is requested but not required
• Use of respirators must not create a hazard to the
worker
• Worker training must include the content of
Appendix D
• Workers must be medically approved
 Additional Information
• www.osha.gov
• 29 CFR 1926.103 (or 29 CFR 1910.134)
• OSHA Compliance Directive (CPL 2-0.120)
• Small Entity Compliance Guide for the Revised
Respiratory Protection Standard
• Respirator manufacturers
• NIOSH certified equipment list
• Health and safety professionals
Questions