OSHA 1910.134 Respiratory Protection governs the use of respirators for any airborne contaminants that engineering controls cannot keep within acceptable limits
When should a respirator be worn?
A respirator should be worn when engineering or administrative controls are not technically possible.
A respirator should be worn when engineering controls are being installed or repaired.
A respirator should be worn when emergency situations occur.
What Are Some Common Terms Related to Disposable Respirators?
Dust – Dry particulate floating in the air.
Fumes – Superheated metal vapor (looks like smoke) which quickly changes to a liquid and then a solid before being breathed into the lungs (very dangerous) – commonly found in welding or foundry operations.
Mist – Liquid particulate floating in air, such as oil, acid, paint, or pesticide mist.
OSHA (Occupational Safety and Health Administration) – Federal agency with safety and health regulatory and enforcement authority for most U.S. industry and business.
NIOSH (National Institute of Occupational Safety and Health) – Federal agency that conducts tests on and certifies respirators which are used in the workplace. In order for a respirator to be used in the workplace for respiratory hazards, that respirator must be NIOSH approved.
PEL (Permissible Exposure Limit) - This is the legally enforced exposure limit for a substance established by OSHA. The PEL indicates the permissible concentration of air contaminants to which nearly all workers may be repeatedly exposed 8 hours a day, 40 hours a week, over a working lifetime without adverse health effects. Respiratory protection is required once these PEL’s are exceeded.
TLV (Threshold Limit Value) – This is a term used by the ACGIH (American Conference of Governmental Industrial Hygienists) to express the airborne concentration of a material to which nearly all persons can be exposed day after day, without adverse effects. Most of the time, the PEL and TLV will be the same for a given contaminant.
Protection Factors - These factors are used to describe the various levels of respiratory protection and indicate their limitations to a chemical. When an employee is properly fit tested, a protection factor will tell us how many times over the PEL that a given NIOSH approved respirator is rated at.
IDLH (Immediately Dangerous to Life or Health) – This is a term used to describe the outcome from an exposure level to a certain chemical. At this level, you will most likely go unconscious within a few seconds of exposure. Neither cartridge nor filter respirators are NIOSH approved for IDLH atmospheres. The only exception is the MSA canister respirator, which can be used for escape from a potential IDLH atmosphere.
Nuisance Levels - Exposure levels to a given contaminant which are below the OSHA PEL. We call them nuisance levels because they may irritate or bother a worker, but are below the concentrations at which OSHA requires the use of a respirator. Basically, manufacturers simply impregnate a little charcoal material into the membrane of a filter for relief of light odors that are below the OSHA PEL.
PPM (Parts per Million) - Part of air by volume of vapor or gas or other contaminant
Odor Threshold - The exposure level in PPM for when you can start to smell a listed contaminant. If a level is not given, the contaminant might either have poor warning properties or it may be a particulate
Common Respirator Abbreviations
OV – Organic Vapor
AG – Acid Gas
OV/AG – Organic Vapor and Acid Gas
AM – Ammonia
FORM – Formaldehyde
MG – Multi-gas
What are the three categories of respirator filtration?
N, R and P. N series respirator filters do not filter for oily substances. R series respirator filters are oil resistant. P series respirator filters are oil proof.
What are the filter efficiencies of a respirator?
100 (99.97%), 99% and 95%. These are efficiencies of respirator filters for particulates down to a 0.3 micron particle size. For reference, a human hair is 40 to 120 microns in diameter.
To summarize, there are the 9 categories of respirator filters:
N Series
R Series
P Series
N95
R95
P95
N99
R99
P99
N100
R100
P100
What are the respirator guidelines regarding daily use of N respirator, R respirator and P respirators?
N-Series Filters – Use and reuse of the N-series filters is subject only to considerations of hygiene, damage and increased breathing resistance.
R-Series Filters - The R-series should only be used for one 8-hour working shift when oil is present
P-Series Filters - Use and reuse of the P-series filters is subject only to considerations of hygiene, damage and increased breathing resistance
How do you know when the disposable respirator needs to be replaced?
When the respirator starts becoming difficult to breathe through, it is time to replace the respirator. The respirator may also get dirtier; however, this is not the main indication that the respirator needs to be changed. As the respirator filters out harmful substances, it will become harder to breathe through the respirator. Replace the respirator when it becomes too difficult or uncomfortable to breathe through.
Can I use a cheaper non-NIOSH approved dust mask in my facility instead of a respirator?
The only way you can use these non-approved nuisance dust masks(instead of a respirator) is to have air monitoring data that proves your work area is below the OSHA PEL. If you are below the PEL, you technically do not need to wear any respirator - such masks may be handed out only for comfort from the small amount of dust that may be floating around.
Will safety or prescription glasses affect the fit of my respirator?
Maybe. Make sure to have the disposable respirator properly fitted on your face before putting on your safety/prescription glass or goggles or the respirator seal could be compromised
Various brands and sizes of disposable respirators can sit at different heights at your nose bridge
Various facial sizes and facial features can also determine how well you are able to wear your glasses/goggles without interference with your respirator.
Some respirator brands do come in various sizes, which might help in lowering the height at the nose bridge
What should you consider when purchasing a disposable respirator?
The size of a disposable respirator is important. Some respirator models are available in small to x-large sizes.
The type of respirator nose piece you choose will affect the fit of the respirator. Try out a metal nose clip and a pre-molded nose shell to see the difference in respirator fit.
The respirator exhalation valve removes hot and humid exhaled air from the respirator, making it much easier to breathe.
A foam nose bridge or face seal will provide a better respirator seal to the face.
Nuisance level charcoal additives are a thin layer of charcoal embedded in the filter media of the respirator. This layer eliminates nuisance odors of either organic vapors or acid gases.
What are the different brands of disposable respirators?
OSHA 1910.134 Respiratory Protection governs the use of respirators for any airborne contaminants that engineering controls cannot keep within acceptable limits
What are the Basics of APR Respirators Uses?
Offer more versatility and longer life than disposable respirators
Can use many different filters/chemical cartridges in a variety of combinations
Replacement parts available for most models
Easy to clean for reuse
Half mask and full facepiece air purifying respirators are negative pressure respirators (creates negative pressure in the mask when you inhale) and PAPR’s are positive pressure respirators, as they have a blower motor which forces air through the cartridge/filter to your breathing area
Any product listed as a “Respirator” is NIOSH approved and meets OSHA compliance
When properly fit tested and used for the correct application, respirators provide protection to 10X the permissible exposure limit (PEL) for a given chemical dust, fume or mist
What Are the Differences Between a Half Mask Respirator and Full Facepiece Respirator?
Half Mask Respirator:
Lower cost to purchase and maintain
Must be used with safety glasses, goggles, and/or a faceshield
Better face seal, compared to a disposable respirator
Full Facepiece Respirator:
Additional eye/face protection from splashes and vapors/gasses penetrating through the eyes
Better overall sealing surface to provide better protection
While more expensive than half mask respirators, prices have been coming down considerably as vendors realizing that these products do not need to be airline compatible
Lenses are fully ANSI compliant for impact protection
What is a Half-Mask Respirator or Full Facepiece Respirator Made of?
PVC is the least expensive respirator option. It is less flexible than rubber or silicone. PVC can develop a memory and lose shape if stored improperly.
Rubber is less expensive than silicone. Rubber does contain latex, which may trigger allergies in some people.
Silicone is the most expensive option. It is very stretchy and face-conforming. It does not develop a memory and is easy-to-clean.
Which Size Respirator Should I Choose?
70% of men and 65% of women will fit into a size Medium respirator. A size small respirator will typically only fit women and size Larges are best for men with larger facial features.
How Should I Store a Respirator?
The best way to store a respirator is to use a respirator cleaning wipe, clean the respirator and store it in a respirator storage bag. Storing a respirator in open air will both reduce the life of the cartridges and affect attempts to create an accurate change out schedule.
What are the different brands of air purifying respirators?
Respirator cartridges are filled with a specially treated activated carbon with a very high adsorption capacity. Gases and vapors passing through the respirator cartridge are attached and held to the surface of the carbon by adsorption.
When Should You Change a Respirator Cartridge?
OSHA requires a respirator change out schedule to replace these respirator cartridges before they expire.
Are Respirator Cartridges Affected by Humidity?
In general, humidity shortens the life of organic vapor respirator cartridges and lengthens the life of acid gas respirator cartridges.
What Other Factors Can Reduce Cartridge Service Life?
Worker Exertion Levels
Warm Temperatures
The Amount of Activated Charcoal in the Cartridge
Exposure to Multiple Contaminants
Storage Conditions – Ideal conditions for a respirator would be in a sealed bag in a low-humidity, room-temperature environment
Why Some Respirator Cartridges NOT Approved for Certain Chemicals?
It might mean that no research has been conducted yet to verify if a chemical respirator cartridge will properly block out that chemical.
The chemical may have poor warning properties, meaning it can’t be smelled very well.
Sorbent material may be ineffective at blocking out the chemical.
Sorbent material may work, but the life of the respirator cartridge may be very short.
What are the different brands of chemical respirator cartridges?
OSHA 1910.134 Respiratory Protection governs the use of respirators for any airborne contaminants that engineering controls cannot keep within acceptable limits.
What Are the Basics of Supplied Air Respirators?
Offer much higher protection from contaminants than air purifying respirators
Can help with heat stress issues, using vortex coolers found on high-pressure models
Large selection of headgear available, including half masks, full facepieces, hoods of varying chemicals resistance and various helmets
Replacement parts available for all respirator models
Supplied air respirators are ideal when certain chemicals cannot be blocked out using traditional chemical cartridges or when the concentration of the chemical might be very high
When properly fit tested and used for the correct application, supplied air respirators can provide protection to 1,000X the permissible exposure level (PEL) for a given chemical
Specific respirator protection factor is determined by the low vs. high pressure air source, continuous flow vs. positive pressure demand, and the type of respirator headgear worn that supplies the air to the respirator breathing zone
From the connection point/air source of an airline system, all respirator components must be the same brand. For example, your hood, vortex cooler and airline hose must all be one brand name, but the breather box, compressor or point of attachment can be of another brand.
What is a Low Pressure Respirator System?
Easy to purchase and set-up with minimal effort
Uses fairly inexpensive and easy-to-maintain respirator pumps
The pumps must be set up in very clean breathing area, as this product simply sucks the air in at the pump and pushes it through the hose to the worker. A small, replaceable filter only takes out larger dust particles in the air at the intake of the pump.
Does not have the ability to add Vortex coolers and heaters due to limited pressure
Cannot be used in as high of a concentration of chemicals compared to most high-pressure systems, but can still go in higher levels of contaminants than cartridge style, negative pressure respirators
Simple cooling techniques can be used with low pressure units, such as immersing coiled airline hose in 5-gallon buckets of ice water
What is a High Pressure Respirator System?
Offers the ability to add Vortex coolers and heaters
If using an industrial compressor or plant air, you must use an air filtration panel with a carbon monoxide monitor. This panel has a series of filters designed to clean up the dirty air that comes out of an industrial compressor which is oil lubricated.
More versatile than low-pressure units, but normally not as portable
Can be reasonable cost, if you already own compressor
Has the ability to run this system from 3 different air supplies:
An industrial compressor that is found in most plants – needs special filters
A portable, breathing air compressor – very expensive
Compressed air from bottles – not for continuous flow, only positive pressure-demand systems
What is Grade D Breathing Air?
Most high pressure airline respirator systems rely on oil lubricated compressors to operate them. Before industrial air may be used to supply NIOSH approved airline respirators, it must be regulated, filtered and monitored to ensure that it meets Compressed Gas Association (CGA) Grade D breathing requirements.
We sell respirator air filtration panels from 3M and Allegro that are designed to meet these requirements
Whether the respirator compressor is portable or installed, piston or screw, OSHA 1910.134 requires that all breathing air compressors be equipped with suitable in-line sorbent beds and filters
1910.134 also requires that oil lubricated compressors be equipped with a high temperature alarm or carbon monoxide monitor, or both. If a carbon moxide monitor is not included, the code requires the air from the compressor be frequently tested to ensure meeting Grade D requirements.
Grade D respirator breathing air requirements are:
19.5% - 23% oxygen
<10 ppm carbon monoxide
<1,000 ppm carbon dioxide
<5 mg/m3 of condensed lubricant oil
Must not have an odor
What is the Required Flow Rate of a Supplied Air Respirator System?
4 CFM (cubic feet per minute) flow rate is required for half-mask and full facepiece respirators.
6 CFM (cubic feet per minute) flow rate is required for respirator hoods and respirator helmets.
What are the Two Systems of Positive Pressure Supply?
Continuous Flow – This is the most common way that air is delivered to the respirator breathing zone. The system will continuously provide the same amount of breathing air, regardless of how fast the user is breathing. Unused air is either forced out of a valve or out the bottom of a shroud on a hood or helmet.
Pressure DemandM – This respirator system uses a regulator, which senses pressure changes in the mask and will deliver only the air that you need. As you start to inhale, the pressure starts to drop inside the mask, causing the regulator to allow pressurized air to enter the breathing zone. Positive pressure demand regulators are used on all SCBA and on certain airline respirators that need a higher protection factor.
What are the Different Brands of Supplied Air Respirators?
A PAPR respirator has a motor which draws air through a specific chemical cartridge or filter to a respirator hood, helmet or facepiece
PAPR respirator units with hoods can be worn without conducting fit testing (medical evaluations still required)
Employees can have beards and wear their own prescription glasses without compromising the respirator seal
PAPR’s are cooler and more comfortable since the user does not need to strain to force air through the respirator filtering media
The worker has a higher level of respirator protection, compared to negative pressure air purifying respirators such as disposable, half-mask or full facepiece respirators
4 cubic feet per minute (CFM) air flow required for half mask respirator or full facepiece respirator styles
6 CFM air flow required for respirator hoods or helmets, no fit testing required
The term HEPA (high efficiency particulate air) filter is used in place of P100 for this category of respiratory protection
Extra hose can be coiled through ice water to make uncomfortable respirator environments more tolerable.
What are the different brands of PAPR Respirators?
What is a Self-Contained Breathing Apparatus (SCBA)Respirator Unit?
Highest level of protection available with a respiratory protection factor of 10,000X
Commonly used for escape from contaminated areas or for clean up of chemical spills
Also used for oxygen deficient and IDLH atmospheres
30 minute cylinders are most common, but 45 and 60 minute units are also available
30 minute cylinders only give approximately 15-20 minutes of actual breathing air when an employee is performing physical activities which speed up their breathing rate
Industrial SCBA respirator units are used to describe a lower cost unit that is not NFPA compliant and cannot be used to fight fires
Fire rated SCBA respirator units must be NFPA compliant and cost considerably more
A NIOSH approved hooded SCBA respirator is available in our catalog from ISI and still must be fit tested
Cylinder comparison:
Aluminum – 5 year hydrostatic testing, no shelf life
Fiberglass (Fully Wound Composite) and Hoop-Wrapped (only wrapped in center) – 3 year hydrostatic testing, 15 year shelf life
Carbon Wrapped – 5 year hydrostatic testing for units built after July 2001 (otherwise 3 years), 15 year shelf life
A hydrostatic test is when a cylinder is checked for leaks or flaws. A hydrostatic test consists of filling the cylinder with water and examining it for leaks or permanent changes in shape. Normally, 150 percent of the operating pressure is used.
How Much Breathable Air Will an SCBA Respirator Provide?
30-minute cylinders only give approximately 15-20 minutes of actual breathing air when employees are performing physical activities. This is due to the increase in breathing rates.
While 30-minute cylinders are the most common, 45- and 60-minute units are also available.
What are the Different Types of Respirator Air Cylinders?
Aluminum, fiberglass and carbon-wrapped respirator cylinders are all available.
What are the different brands of SCBA respirators?
Respirator Fit testing (with the same make and model respirator that the employee will use) must be conducted prior to the initial use and at least annually thereafter. All tight fitting respirators, including SCBA’s, must be fit tested in the negative pressure mode. A user seal check, which an employee performs each time the respirator is worn, does not suffice as a fit test.
What Kind of Respirator Fit Test Methods Should be Used?
Irritant Smoke - This is the easiest and most convenient method. A granular substance is blown through a glass tube via a squeeze bulb. While having no smell, this smoke will produce an involuntary cough, if a leak around the respirator is noted. Most disposable respirators are not approved for this method, as it requires an N or P100 filter to block out the acid mist. A smoke hood is not allowed during the fit test.
Saccharin Mist – This substance has a sweet taste. A hood is used to hold the mist in the breathing zone during the fit test. A nebulizer is used to deliver the mist. This test can be used for any disposable respirators, half-mask or full facepiece, as only an N95 filter or higher is needed to block out this mist.
Bitrex Mist – This fit test is accomplished exactly like the Saccharin test. Bitrex tastes bitter and most employees detect the sensitivity taste slightly quicker than when using Saccharin.
Banana Oil – This material requires an organic vapor cartridge to block this fit test chemical out. This test is viewed by most professionals as the least desirable method because of the complicated nature of the test. Solutions of the concentrated chemical must be carefully measured out into mason jars. A separate room is needed to conduct the sensitivity screening phase of the fit test.
Quantitative Fit Testing – This is a more accurate and reliable fit test method. This machine can cost over $7,000 and is commonly used by larger companies and consultants for when a fit factor of 100 or higher is needed.
Who Should Clean and Maintain the Respirator?
The cleaning, disinfecting and repair of a respirator should be done by those who are trained in the proper respirator maintenance procedures. Most companies will require each individual employee to be responsible for the cleaning and maintenance of their own respirator.
Besides Annually, When Else is Respirator Retraining Necessary?
Whenever there is a change in the level of workplace hazards, or when the respiratory protection program is updated or when an employee has not understood the program sufficiently enough.
How Do I Get Started with a Respirator Protection Program?
Using respiratory protection, according to OSHA, should be your last resort. First, you must conduct a detailed hazard evaluation of your facility and determine that other preferred preventive measures, such as: implementing engineering controls, materials substitution, and administrative controls will not be effective in controlling them.
What Procedures Should be Included in the Respiratory Protection Program?
Selecting a respirator
Medical evaluations for employees using a respirator
Fit testing for tight fitting a respirator
Using a respirator in normal and emergency situations
Cleaning, disinfecting, storing, inspecting, repairing, maintaining and discarding a respirator
Ensuring adequate quality and quantity of breathing air
Annual training required for respirator use in normal and emergency situations
Annual training in respirator use for fit, usage, limits and capabilities
Program reevaluation and recordkeeping
Who Should Administer the Respiratory Protection Program?
An appropriately trained program administrator must be designated to oversee the program. Appropriately trained means a person with adequate training, knowledge or experience to administer a respiratory protection program depending upon its complexity. If inspected, an OSHA inspector will review the written program and interview the administrator to determine the person’s capability to run an effective program. There is no mention of any specific training courses.
How Often Should the Written Respiratory Protection Program be Updated?
Whenever there is a change in workplace hazards, respirator choices, fit testing procedures or the nature of the employees’ work, the program must be updated. OSHA is working on a Small Entity Compliance Guide with sample respirator program to provide employers with guidance on putting a program in place. It will be available at the OSHA Web site.
Can a Tight-Fitting Respirator, When Used Voluntarily, be Worn Over a Beard?
Yes, provided the respirator is used voluntarily and there is no airborne hazard
Who Can Perform a Medical Evaluation?
Only healthcare professionals who are licensed, certified or registered by the state or certification agencies can perform these evaluations. A sample of the medical questionnaire appears on OSHA’s website. (Conney Safety offers online medical evaluations at a nominal cost of $25. An employer can opt to provide a physical exam over a questionnaire as long as it elicits the same kind of information. The cost and time for performing these evaluations must be borne by the employer.
When Should a Medical Evaluation be Done?
A medical evaluation should be done before any respirator fit test, because some employees may not be able to use respirators even for the duration of the test.
Do Temporary and Seasonal Employees Require a Medical Evaluation?
Yes, any employee who is required to wear a respirator requires a medical evaluation.
What if An Employee Declines to Undergo a Medical Evaluation?
Then they must provide a copy of their own medical evaluation to the employer. Otherwise, they cannot continue to use a respirator.
Does the Medical Evaluation Need to be Repeated Annually?
No, according to the standard, it must be repeated only in the following situations:
If a doctor, supervisor, respirator program administrator or person conducting a fit test indicates an employee needs to be reevaluated.
If the respiratory protection program was written to require it.
When an employee reports signs or symptoms that are related to the ability to use a respirator.
When a change in workplace conditions, such as temperature, physical work effort or the use of protective clothing, may result in a substantial increase in the physiological burden placed on an employee.
How Do I Set Up a Respirator Training Program?
Overall, the respirator standard is performance-based, which means the employees who use the respirators should be able to demonstrate their knowledge of how to use, clean and maintain their respirator, as well as know its limits and capabilities, especially in emergency situations. This can be tested either by asking questions or observing the use. Conney Safety offers online respiratory training for customers who use 3M respirators. Click here for training
If you have a customer that has yet to put a respirator program in place, consider discussing our Safety Made Simple System to help meet their needs. The program for respiratory protection is an easy step-by-step system developed for employers that are not that familiar with the regulations. It will assist them in putting a written program together and training their employees.
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