21 Oct Respirator Program – Respiratory Protection

Respirator Program – Respiratory Protection

A respirator program is required when employees must use respirators to protect against hazardous airborne contaminants, oxygen-deficient atmospheres, or other respiratory hazards. Respirators are considered an important line of defense, but whenever feasible, hazards should first be eliminated or controlled through engineering and work-practice controls.

Respirators must be selected and used as part of a properly administered written respiratory protection program that meets applicable OSHA requirements.

When Are Respirators Required?

Respiratory protection may be required when:

• Employee exposure exceeds an applicable OSHA Permissible Exposure Limit (PEL).
• Engineering and work-practice controls cannot adequately reduce exposure.
• Engineering controls are being installed or implemented.
• Employees perform certain tasks for which respiratory protection is specifically required.
• Employees respond to emergencies, spills, or releases involving hazardous airborne contaminants.
• The atmosphere is oxygen-deficient or potentially Immediately Dangerous to Life or Health (IDLH).

Never enter an unknown, oxygen-deficient, or potentially IDLH atmosphere with an air-purifying respirator.

Written Respiratory Protection Program

When respirator use is required, the employer must establish and maintain a written program with worksite-specific procedures.

As applicable, the program must address:

• Respirator selection.
• Medical evaluations.
• Fit testing.
• Proper respirator use.
• Procedures for IDLH atmospheres.
• Cleaning and disinfecting.
• Inspection and maintenance.
• Proper storage.
• Breathing-air quality and use for supplied-air respirators.
• Employee training.
• Program evaluation.
• Recordkeeping.

A qualified Program Administrator must oversee and evaluate the respiratory protection program.

Evaluate the Hazard First

Before selecting a respirator, determine the respiratory hazards employees may encounter.

The evaluation should consider:

• Identity of the contaminant.
• Concentration or expected concentration.
• Applicable occupational exposure limits.
• Physical and chemical properties.
• Oxygen concentration when applicable.
• Work being performed.
• Length and frequency of exposure.
• Potential emergency conditions.
• Whether an IDLH atmosphere could exist.

If the employer cannot identify or reasonably estimate employee exposure, the atmosphere must be considered IDLH when required by OSHA’s respiratory protection standard.

Engineering Controls First

Respirators should not automatically be the first method selected to control routine airborne exposures.

Where feasible, use engineering controls such as:

• Local exhaust ventilation.
• General ventilation.
• Enclosures or isolation.
• Process modification.
• Wet methods.
• Substitution with less hazardous materials.

Respiratory protection is used when these controls are not feasible, while they are being implemented, or when they do not adequately control the hazard.

Respirator Selection

The respirator must be appropriate for the specific hazard and conditions of use.

Selection should consider:

• Type and concentration of contaminant.
• Respirator limitations.
• Required protection factor.
• Work activities and physical demands.
• Duration of use.
• Environmental conditions.
• Emergency or escape requirements.

Respirators used to comply with OSHA requirements must be NIOSH-approved and used according to the conditions of their certification.

Never substitute cartridges, filters, canisters, or other components that are not approved for the respirator being used.

Medical Evaluation

Employees must receive a medical evaluation to determine their ability to safely wear a respirator before fit testing or required respirator use.

The evaluation must be performed by a physician or other licensed health care professional (PLHCP) using the OSHA medical questionnaire or an equivalent method permitted by the standard.

Additional medical evaluation may be necessary when:

• An employee reports symptoms related to respirator use.
• A PLHCP, supervisor, or Program Administrator determines reevaluation is necessary.
• Information from the respiratory protection program indicates a need.
• Workplace conditions substantially increase the physiological burden on the employee.

Fit Testing

Employees required to wear a tight-fitting respirator must be fit tested with the same make, model, style, and size of respirator they will use.

Fit testing is required:

• Before initial use.
• Whenever a different respirator facepiece is used.
• At least annually thereafter.
• Whenever physical changes could affect respirator fit.

Such changes may include significant weight change, facial scarring, dental changes, cosmetic surgery, or other changes affecting the face-to-facepiece seal.

A fit test is different from the user seal check, which must be performed each time a tight-fitting respirator is put on.

Facial Hair and the Respirator Seal

Employees must not wear tight-fitting respirators when facial hair or another condition:

• Comes between the sealing surface and the face.
• Interferes with valve function.
• Prevents an adequate seal.

Eyeglasses, goggles, PPE, or other equipment must also be worn so they do not interfere with the respirator seal.

Cartridges, Canisters, and Filters

Employees must use only the cartridges, canisters, or filters approved for the contaminant and respirator.

For respirators protecting against gases or vapors, employers must establish an appropriate change schedule when required. Employees must not rely solely on odor, taste, or irritation to determine when a cartridge needs replacement.

Filters and cartridges should be replaced according to the respiratory protection program, manufacturer requirements, and established change schedule.

Inspection, Cleaning, and Storage

Respirators must be properly maintained so they remain effective.

Employees should:

• Inspect respirators before each use.
• Check straps, valves, facepieces, filters, cartridges, and connections.
• Remove defective respirators from service.
• Clean and disinfect respirators at required intervals.
• Store respirators where they are protected from contamination, dust, sunlight, extreme temperatures, moisture, chemicals, and physical damage.

Respirators used for emergency situations require additional inspection and documentation.

Supplied-Air Respirators and SCBA

When atmosphere-supplying respirators are used, breathing air must meet applicable OSHA quality requirements.

Systems must be properly designed and maintained to prevent contamination of breathing air. Employees using supplied-air respirators or self-contained breathing apparatus (SCBA) must receive training specific to the equipment and hazards involved.

Employee Training

Employees required to use respirators must receive training before use and at least annually thereafter.

Training must include:

• Why the respirator is necessary.
• How improper fit, use, or maintenance can reduce protection.
• Respirator capabilities and limitations.
• Proper inspection and donning.
• User seal checks.
• Proper use during routine and emergency conditions.
• Maintenance and storage.
• Recognition of medical signs and symptoms that may limit effective respirator use.
• Applicable requirements of the respiratory protection program.

Retraining is required when workplace conditions or respirator types change, when an employee demonstrates inadequate knowledge or use, or whenever other circumstances indicate retraining is necessary.

Program Evaluation

The respiratory protection program must be evaluated periodically to ensure it continues to protect employees effectively.

Employees should be consulted regarding respirator fit, comfort, use, and any problems encountered.

Changes in chemicals, work processes, equipment, exposure levels, or jobsite conditions should trigger reevaluation of respiratory hazards and the protection being provided.

Remember

An effective respirator program involves much more than handing an employee a respirator. The hazard must be evaluated, the correct respirator selected, the employee medically cleared and fit tested, and the equipment properly used, inspected, maintained, and stored.

Control the hazard first. Select the right respirator. Fit it correctly. Maintain it properly.

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