Respiratory Protection in the Workplace- A Guide for Employers - Department of Industrial Relations
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Respiratory Protection
in the Workplace
– A Guide for Employers
Department of Industrial Relations
Division of Occupational Safety and Health
Rev. April 2021
Contents About This Guide1 When Do Respirators Have To Be Used?3 What is a Harmful Exposure? 3 How to Identify Harmful Exposures 3 How to Control Harmful Exposures 5 Voluntary Use of Respirators 6 Wildfires 6 Aerosol Transmissible Diseases 7 Immediately Dangerous to Life or Health (IDLH) Environments 7 Types of Respirators8 Air-purifying Respirators (APR) 8 Atmosphere Supplying 9 Negative and Positive-pressure Respirators 10 Written Respiratory Protection Program11 Selection of Respirators 12 Medical Evaluations 14 Fit Testing of Tight-fitting Respirators 15 Proper Respirator Use 17 Maintenance and Care of Respirators 19 Breathing Air Quality and Supply 20 Training and Information 22 Program Effectiveness Evaluation 22 Recordkeeping23 Additional Resources24 Abbreviations and Acronyms25
About This Guide
This guide is not meant to be a substitute for, or a legal
interpretation of, the occupational safety and health
standards. Please see the California Labor Code and Title
8 of the California Code of Regulations for detailed and
exact information, specifications, and exceptions.
Section 5144, Respiratory Protection is the primary respiratory
protection standard that all employers with employees using respirators
must effectively comply with. However, note that there are other
regulations covering certain airborne, substance-specific hazards that
also include additional respirator use requirements, such as:
• General Industry Safety Orders
□ Section 5141, Control of Harmful Exposures to Employees
□ Section 5141.1, Protection from Wildfire Smoke
□ Section 5150, Ventilation and Personal Protective Equipment Requirements for Welding,
Brazing and Cutting
□ Section 5151, Ventilation and Personal Protective Equipment Requirements for Abrasive
Blasting Operations
□ Section 5153, Ventilation and Personal Protective Equipment Requirements for Spray
Coating Operations
□ Section 5190, Cotton Dust
□ Section 5192, Hazardous Waste Operations and Emergency Response
□ Section 5197, Food Flavorings Containing Diacetyl
□ Section 5198, Lead
□ Section 5199, Aerosol Transmissible Diseases
□ Section 5199.1, Aerosol Transmissible Diseases–Zoonotic
□ Article 110, Regulated Carcinogens
• Construction Safety Orders
□ Article 4, Dusts, Fumes, Mists, Vapors, and Gases
T8CCR, section 5194, Hazard Communication requires every employer to develop, implement,
and maintain at the workplace a written hazard communication program for their employees. This
includes gathering information on the hazardous chemicals your employees are exposed to, such
as:
• A list of the hazardous chemicals known to be present.
• The Safety Data Sheets that correspond to the listed chemicals, which will be an important
source of information when determining when respiratory protection will be required, and what
types should be used.
1This guide is intended to provide an overview of respiratory protection – not comprehensively
address all possible aspects and types of respirators.
Copyright © 2021 State of California, Department of Industrial Relations.
Permission granted to display, perform, reproduce and distribute exclusively for
nonprofitandeducationalpurposes,andmaynotbeusedforanycommercial
purpose. All other rights reserved.
2When Do Respirators Have To Be Used?
Respirators are protective devices used to reduce workers’ harmful exposures to
airborne hazards, including oxygen-deficient atmospheres.
What is a Harmful Exposure? How to Identify Harmful Exposures
Airborne harmful exposures to your employees There can be a number of things to consider
can be in the form of: when trying to accurately determine what your
employees’ airborne hazardous contaminant
• Dusts, fumes, mists, smoke, vapors or gases exposures are. The following is a brief overview.
that are:
□ In excess of any permissible limit Factors in Assessing Respiratory Hazards
prescribed by T8CCR, section 5155.
□ Of such a nature by inhalation as to result • Identify the respiratory hazards your
in, or have a probability to result in, injury, employees are exposed to and determine
illness, disease, impairment or loss of what the corresponding Cal/OSHA
function. allowable exposure levels are. A good
• Oxygen-deficient atmospheres that occur place to start is the Safety Data Sheet
when there is less than 19.5% oxygen (SDS) for each of the materials your
present. employees work with.
Some important points to take from section 5155, Airborne Contaminants
• These are assigned concentration limits to airborne contaminants that nearly all workers
may be exposed to daily during a 40-hour workweek for a working lifetime without adverse
effect. Also, because of some variation in individual susceptibility, an occasional worker
may suffer discomfort, aggravation of a preexisting condition or occupational disease upon
exposure to concentrations even below the assigned exposure levels.
• Harmful exposure to any substance not listed must be controlled in accordance with T8CCR,
section 5141, which may include use of respiratory protection.
• Some of the listed chemicals have an “S” (skin) notation, which means they can be
absorbed into the bloodstream through the skin, the mucous membranes, or the eye. They
can contribute to the overall exposure and may require other forms of protection besides
respiratory.
• There are three types of exposure limits (some of the listed chemicals can have more than
one type of assigned exposure limit):
1. C (ceiling): maximum concentration of an airborne contaminant that an employee may be
exposed to at any time.
2. PEL (permissible exposure level): The maximum permitted 8-hour time-weighted average
concentration of an airborne contaminant.
3. STEL (short term exposure level): A 15-minute (or sometimes other than 15 minutes,
as indicated) time-weighted average exposure which is not to be exceeded at any time
during a workday, even if the 8-hour time-weighted average is below the PEL.
3• There may be instances where there directly measure exposure levels or collect air
are no assigned Cal/OSHA exposure samples that require lab analysis. Measuring
limits, in which case there may be other your workers’ exposures to respiratory
occupational exposure limits, such as hazards can be complex. It involves knowing
NIOSH RELs (recommended exposure how to use and calibrate sampling equipment.
levels) and ACGIH TLVs (threshold limit It also involves understanding the effects of
values), or other toxicological or industrial numerous workplace environmental factors,
hygiene publications that can be used. such as ambient temperatures and humidity,
• Determine the state and the physical form process temperatures, general facility
of the chemicals. For instance, are they conditions (e.g., general and local ventilation)
solids, liquids, gases, or a mixture of these and chemical interferences and interactions.
forms? What are the particle sizes (where
applicable)? Do the liquids and solids give The following are some questions that
off vapors or do they form dusts or mists? need to be answered when assessing the
Does an oxygen-deficient atmosphere concentration of air contaminants:
exist in your workplace? Are any
combination of these hazards present? • What are the exposure levels under
• Evaluate the extent of the hazards posed normal conditions of use?
by the chemicals that may be present. • Are short-term peak and full-shift average
For instance, are employees working exposures—where applicable—being
in conditions that exceed or fall below assessed?
acceptable exposure limits? How many • Are the respirable dust fractions being
employees are exposed? determined for substances that have
• The person supervising, directing or respirable dust PELs?
evaluating the monitoring and exposure • What are the exposure levels in a
control methods must be competent in reasonably foreseeable emergency?
industrial hygiene practices. • When are you going to perform air
• Determine if there are routes of exposure monitoring and for how long?
other than the lungs, such as the skin, that • Are exposures constant throughout a shift,
are of concern. or are there processes that create high
• Address additive effects where there are concentrations for short periods?
mixtures of chemicals as some of them • Will you monitor all employees or a
may affect the same target organ. In this representative number of exposed
circumstance, additive exposure levels employees?
need to be determined as described in the • Did you assume worst-case conditions
Appendix to section 5155. to evaluate the highest foreseeable
employee exposure levels?
Reference section 5155(e), Workplace • How much air monitoring is needed to
Monitoring. make a reliable evaluation?
• Are the employees’ exposure
Methods for Assessing Employees’ assessments taking into consideration
Exposures Ceiling, STEL and PEL exposure limits,
where applicable? Employees may not be
Air Monitoring is used to assess the overexposed to the PEL, but they might be
concentration of air contaminants that your at the Ceiling or STEL.
employees may be breathing. Measurements
can be made by using instruments that
4“Respirable dust fraction.” With some You may need outside help with all this. Expert
airborne substances, the smaller particles that assistance is available from safety and health
can be inhaled into the deeper parts of the professionals employed by:
lungs—“respirable”—canbe significantlymore
hazardous.Referencesection 5155, Table • Workers’ compensation insurance carriers
AC-1 Footnote “n”forthedefinitionof what a • Cal/OSHA Consultation Service
respirable dust fraction is. • Private consulting firms
• Respirator product vendors
Breathing zone air monitoring is the best • Industry associations
and most reliable method for assessing
employees’ exposures to air contaminants. Safety and health professionals can also help
Typically, an employee wears a personal you determine: how to reduce employees’
air pump that draws air through sampling exposures so they don’t have to wear
media in the breathing zone of the employee. respirators; what kind of respirator and
The breathing zone is the area around the filters should be used and how to fit test the
employee’s head and shoulders where the respirators.
contaminants collected represent what the
worker is inhaling. The information you collect on what your
employees are exposed to, and how much,
In some instances, it may also be useful to will be important when it comes to selecting
collect area air samples at fixed locations the right respirator and determining how often
in and around the work area. This method of cartridges need to be changed out. Keep
air monitoring is used more for: screening; in mind that this information also becomes
establishing boundaries of high exposure subject to section 3204, Access to Employee
areas; evaluating the effectiveness of control Exposure and Medical Records.
measures; supplementing breathing zone air
monitoring and obtaining background airborne How to Control Harmful Exposures
concentrations.
Ideally, substitute with less toxic materials. If
Objective Data is specific and reliable that is not an option, then you must reduce
information that indicates whether the use or those exposures by one, or a combination, of
handling of a product or material will release the following control measures:
concentrations of a respiratory hazard that
exceed a level that would trigger the need 1. Engineering control measures, such as
for respirator use. For example, you can use enclosing or isolating the process, or
data: using dilution or local exhaust ventilation,
whenever feasible.
• On the physical and chemical properties 2. Applicable administrative controls, such as
of air contaminants in combination with limiting exposure by adjustment of the work
information on room dimensions, air schedule and using work practice controls
exchange rates and contaminant release (e.g. prohibiting use of dry sweeping or
rates to estimate the maximum exposure compressed air to clean off surfaces and
that could be anticipated in the workplace. wetting dusty materials before they are
• Obtained from other exposure disturbed), when engineering controls are
assessments done on similar work not feasible or do not achieve sufficient
operations involving the same hazard reduction.
contaminants under similar conditions. 3. Using appropriate respirators as a last
resort:
• When the controls listed above are not
feasible.
5• While the controls are being instituted. Required Under the Standard. Employees
• When the controls are not sufficient to must understand the limitations of the
reduce respiratory hazards to a level respirators and how to use and maintain
below established exposure limits. them.
• During reasonably foreseeable
emergencies. Filtering facepiece respirators (disposable
“dust masks”). When it comes to voluntary use
Refer to T8CCR sections 5141, Control of of these types of respirators:
Harmful Exposure to Employees, and 5144(a)
(1) Respiratory Protection for details. • A written respiratory protection program is not
required.
Also refer to the substance-specific regulations • Employers must still provide employees with
in articles 109 and 110 of the General Industry the information in section 5144, Appendix D,
Safety Orders, and article 4 of the Construction Information for Employees Using Respirators
Safety Orders for additional requirements, such When Not Required Under the Standard.
as:
Refer to Types of Respirators (page 9), below,
• Selection of the proper type of respirators to for more information on what is considered a
be used for particular hazardous substances filtering facepiece respirator.
(including filtering facepiece respirators).
• Limitations on using administrative controls. Wildfires
Voluntary Use of Respirators Employers should
reasonably
Voluntary use of a respirator is allowed when all anticipate that
of the following conditions have been met: employees may be
exposed to wildfire
1. An employee requests a respirator even smoke. Smoke from
though the use of one is not required by you wildfires contains
(the employer). chemicals, gases and fine particles that can
2. A Cal/OSHA standard does not require one harm health. T8CCR, section 5141.1 establishes
and you have determined that its use is required safety and health protection measures
not necessary to protect the health of the for employees—including the use of respirator
employee. protection—when the current Air Quality Index
3. It will not in itself create a hazard. (AQI) for PM2.5 is 151 or greater.
When used voluntarily, only the following written Employers are required to provide employees
respiratory protection program elements must be with NIOSH-approved respiratory protection in
met: accordance with T8CCR, section 5144 as follows
for:
1. Employee medical evaluation and approval to
wear a respirator. • Voluntary use when the current AQI for
2. Procedures for cleaning, storing and PM2.5 (solid particles and liquid droplets
maintaining respirators. suspended in air, known as particulate
3. Training – provide employees with the matter, with an aerodynamic diameter of 2.5
information contained in Appendix D micrometers or smaller) is 151 or greater but
of T8CCR section 5144, Information for less than 500. Employees must be trained
Employees Using Respirators When Not on the information in Appendix B of T8CCR,
section 5141.1.
6• Mandatory use when the current AQI for supplying respirators or respirators certified by
PM2.5 exceeds 500. NIOSH for escape.
Aerosol Transmissible Diseases Confined spaces
• T8CCR, section If the IDLH
5199 establishes environment is
employee within a confined
protection space, then other
requirements Cal/OSHA T8CCR regulations can come
that address into play, such as:
occupational exposure to aerosol
transmissible diseases (ATD). • Construction: article 37
• General Industry: section 5157
ATDs are defined as diseases for which • Grain handling facilities: section 5178
droplet or airborne precautions are required, • Telecommunication vaults: section 8616
as listed in Appendix A of section 5199. • Ship building, repairing, breaking:
These diseases can be transmitted by section 8355
infectious particles or droplets through • Electrical utility operations within
inhalation or direct contact with the mucous underground vaults: sections 2700,
membranes of the eyes or respiratory tract. 2943 and 2943.1
The disease-causing aerosols covered by this
regulation are pathogens, such as bacteria Section 5158 confined space requirements
and viruses. apply to:
• T8CCR, section 5199.1 establishes • Construction activities defined in section
employee protection requirements that 1502
address occupational exposure to zoonotic • Agricultural operations defined in
ATDs. section 3437
• Marine terminal operations defined in
Sections 5199 and 5199.1 can require use of section 3460
respiratory protection and are applicable to • Telecommunication manholes and
specific types of workplaces and conditions, so unvented vaults regulated by section
be sure to review the scope and application of 8616
these two standards to see if and how they affect • Grain handling facilities regulated by
your employees. section 5178
• Natural gas utility operations within
Immediately Dangerous to Life or distribution and transmission facility
vaults defined in Title 49 Code of Federal
Health (IDLH) Environments
Regulations Parts 191, 192 and 193
Paragraphs (d) and (g) of section 5144 establish
protection requirements for employees that must Also refer to Section 5192(q), Emergency
work in an IDLH condition – an atmosphere that: Response to Hazardous Substance Releases,
poses an immediate threat to life; would cause should it be applicable to your workplace.
irreversible adverse health effects or would
impair an individual’s ability to escape from a
dangerous atmosphere. The control measures
include the use of specific types of atmosphere-
7Types of Respirators
This guide provides a brief overview. Please review the following for more detailed
information:
• OSHA
• NIOSH
There are a variety of different types of respirators that are typically categorized as either air-purifying
or atmosphere-supplying, with some being further sub-categorized as:
• Positive or negative-pressure
• Tight or loose-fitting
• Continuous-supply, demand or pressure-demand
• Half or full-face
What is important is to make sure the appropriate one is being used given the:
• Type and concentration of airborne contaminants in question.
• Comfort of the user. The more uncomfortable it is, the less likely it will be used, or used properly.
Be sure to also consider heat-stress issues associated with the type of respirator selected for use.
Air-purifying Respirators (APR) • Tight-fitting elastomeric
respirators with half or full-face
APRs work by removing gas, vapor and masks that have disposable
particulate contaminants from the air through the filters/cartridges/canisters.
use of filters, cartridges or canisters. There is no • Powered air-purifying
one filter or cartridge/canister that removes all respirators (PAPRs) that have
contaminants, so it is important to use the right a loose-fitting hood, helmet or
one for the air contaminants of concern. tight-fitting facepiece. A battery-
powered fan pulls air through
For example: in an organic solvent-based paint filters, cartridges or canisters
spray operation you would probably need a instead of the lungs having to
combination of a particulate/aerosol pre-filter and do the work.
an organic vapor cartridge.
There are nine classes of particulate filters,
All filters/cartridges have a NIOSH approval label consisting of three levels of filter efficiency,
and are color-coded. each with three categories of resistance to filter
efficiency degradation.
Examples of air-purifying respirators include:
The three levels of filter efficiency are 95%, 99%,
• Disposable filtering and 99.97% (referred to as “100”).
facepiece respirators (dust
masks) used for airborne The three categories of resistance to filter
particulates. efficiency degradation are labeled N, R, and P.
8N = not resistant to oil • Combination respirators that
R = somewhat resistant to oil use an airline to an outside
P = strongly resistant to oil source, along with an auxiliary
SCBA that can be used to
The class of filter will be clearly marked on escape from a hazardous
the filter, filter package or respirator box. For environment should the airline
example, a filter marked N95 would mean an fail, and always a tight-fitting
N-series filter that is at least 95% efficient. facepiece.
• Escape-only respirators that are intended for
Chemical cartridges that include particulate filter use only during an emergency exit. Escape-
elements will carry a similar marking that pertains only respirators cannot be used to enter an
only to the particulate filter element. area that has a hazardous atmosphere.
Filtering facepiece respirator (dust mask) Atmosphere-supplying respirators can also be
means a negative pressure particulate respirator categorized as continuous-flow, demand, or
with a filter as an integral part of the facepiece or pressure-demand.
with the entire facepiece composed of the filtering
medium. Those that are NIOSH-approved will Continuous-flow means air is supplied to the
have two head straps and be identified with the users (typically via an airline) at set air pressures
N, R or P and a 95, 99 or 100 designation. Some and flow rates, regardless of whether they
models have an exhalation valve. “demand” it – i.e., they don’t have to inhale to
activate a regulator to trigger in-flow of air. This
Atmosphere-Supplying type of respirator is typically under positive
pressure and often does not rely on a tight-fitting
Atmosphere-supplying respirators work by facepiece-to-face seal.
using breathing air that meets specified quality
standards and consist of a loose-fitting hood, The pressure-demand feature provides the
helmet or a tight-fitting half or full-facepiece. highest protection factor and admits breathing
The breathing air is supplied by a compressor or air to the facepiece when the positive pressure
compressed air cylinders. inside the facepiece is reduced by inhalation –
i.e., the user “demands” it. A positive pressure is
Examples of atmosphere-supplying respirators maintained at all times so if there is any leakage,
include: it will be to the outside of the facepiece, not in.
• Airline respirators There are also demand supplied-air respirators
where the breathing air that are similar to pressure-demand, except they
is supplied through an are not designed to maintain a positive pressure
airline from a source within the face mask at all times – i.e., the user
outside the contaminated must inhale, creating a negative pressure within
work area, and typically the mask, before the regulator activates and
consist of a loose-fitting provides air.
hood, helmet or tight-fitting
facepiece. Certain types of atmosphere-supplying
• Self-contained breathing respirators are mandated for use in IDLH
apparatus (SCBA) that atmospheres, such as:
allow the user to carry a
compressed breathing air • A full facepiece pressure-demand SCBA.
cylinder with them, and • A combination full facepiece pressure-
always used with a tight-fitting facepiece. demand airline respirator with an auxiliary
SCBA.
9Other types of atmosphere-supplying respirators Negative-pressure respirators are tight-fitting
must be used in situations such as: respirators that work by creating pressure
differences between the air inside and outside the
• In atmospheres for which there are no respirator. With APRs, when the user breathes
approved air-purifying filters. in, the pressure inside the facepiece becomes
• During certain welding, brazing, or cutting negative, which pulls air into the facepiece
operations that involve toxic metals. through filters/cartridges. Examples typically
Reference T8CCR, section 5150. include filtering facepiece respirators (“dust
• During procedures that involve higher masks”) as well as elastomeric half and full-
concentrations of airborne contaminants, facepiece respirators. With air-supply respirators,
including abrasive blasting, where a higher the creation of a negative pressure when the user
protection factor is warranted. breathes in activates a regulator that supplies air.
• Emergency escape from a hazardous Proper fit testing becomes important given any
environment (e.g., escape-only respirators). leakage that may occur between the face and
facepiece.
Reference Breathing Air Quality and Supply
- Airline Systems (page 21) for additional Positive-pressure respirators are designed to
guidance on some of the various issues that must maintain a positive pressure within the facepiece
be addressed in order to ensure a safe airline even when the user inhales. Examples include
respirator system. loose-fitting powered air purifying respirators
(PAPR), pressure-demand self-contained
Negative and Positive-pressure breathing apparatus (SCBA) with a tight-fitting
Respirators facepiece, and continuous-flow, loose or tight-
fitting airline respirators.
Air-purifying and atmosphere-supplying
respirators may also be classified on the basis
of their functioning as either negative or positive-
pressure respirators.
10Written Respiratory Protection Program
Invest the time to have in-house knowledge about respirators and how they should
be used in your workplace. The person you designate to run your respirator program
will be the Respiratory Protection Program Administrator, and they will have specific
duties and responsibilities that are detailed in T8CCR, section 5144, Respiratory
Protection. Make sure they have the training and necessary knowledge to carry this
out.
Establish, in writing, how all of the required elements and site-specific procedures will be effectively
implemented in your workplace, as summarized in the following flow chart:
Are respirators necessary to protect the health of the
employees (or required by the employer)?
Yes No
Establish and implement a written Does the employer permit voluntary use
respirator program with the following of respirators?
procedural elements:
• Selection of Respirators
• Medical Evaluation Yes No
• Fit Testing of Tight-fitting Respirators
• Proper Respirator Use
• Maintenance and Care of Respirators Stop
• Breathing Air Quality and Supply
• Employee Training and Information
• Program Effectiveness Evaluation Does the only use of respirators involve
• Recordkeeping the voluntary use of filtering facepiece
respirators (dust masks)?
Yes No
• The employer determines that the • The employer determines the respirator
respirator itself does not create a hazard. itself does not create a hazard.
• The employer must provide users with the • The employer must provide users with the
information contained in Appendix D of information contained in Appendix D of
Section 5144. Section 5144.
• No written respirator program required. • The employer must establish and
implement those elements of written
respirator program that are necessary to
ensure that the employee is medically
able to use the respirator and it is cleaned,
stored and maintained.
11Be sure the manufacturers’ instructions are always available to the users, since that will be a critical
source of information when ensuring respirators are properly used and maintained. Consider
incorporating the manufacturers’ instructions for all of the respirators your employees use into your
written respiratory protection program.
The Fed OSHA Small Entity Compliance Guide for the Respiratory Protection Standard has
checklists for each of the required respirator program elements that you may find helpful.
Selection of Respirators Respirator cartridge change out
Once you know what your employees are A cartridge change-out schedule will be
exposed to, how much of an exposure there necessary for air purifying respirators
is, and the conditions in which respirators must used for protection against gases and
be used, you are now ready to start selecting vapors if an end-of-service-life indicator
which respirators employees will be using. The (ESLI) is not available. An atmosphere-
following are some important considerations supplying respirator may be more practical
when developing your written respirator program if the change-out schedule is short. Refer
selection procedures: to Proper Respirator Use (page 17) for
more information on ESLI and change-out
NIOSH certification schedules.
Only select a NIOSH-certified respirator and Assigned protection factors (APF) and
only use it in compliance with the conditions maximum use concentration (MUC)
of its certification. Those conditions will
include the specific contaminants in question, Will the type of respirator you are considering
the maximum exposure concentrations provide sufficient protection given the
allowed, as well as the acceptable respirator expected exposure levels?
components.
The APF means the workplace level of
Look for the NIOSH approval label, which respiratory protection that a respirator is
includes: expected to provide to employees when
the employer implements a continuing,
• The approval number effective respiratory protection program.
• Protection level For example, a respirator with an APF of
• Component with part number 10 means that it is expected to reduce the
• Caution and limitation statements in the user’s exposure to the specific airborne
form of a table or matrix of information contaminant of concern by a factor of
10, assuming that the user has passed
The NIOSH Approval Label Fact Sheet a fit test to that model respirator and is
provides additional information. wearing it properly.
Some filtering facepiece respirators are The MUC means the maximum
NIOSH-certified while others are not. Refer atmospheric concentration of a hazardous
to the NIOSH Respirator Trusted-Source substance from which an employee
Information Web page to help you make can be expected to be protected when
sure you only use NIOSH-certified filtering wearing a respirator, and is determined
facepiece respirators. by the assigned protection factor of the
12respirator and the exposure limit of the of 350 PPM. Assuming the method used
hazardous substance. For example, if the to determine employee exposures has an
PEL for a contaminant is 50 PPM (parts SAE of 12%, then the actual employee
per million) and the respirator has an APF exposures are plus or minus 12% of 335
of 10, then the MUC is 10 x 50 = 500 PPM, which means actual employee
PPM. exposure is somewhere between 295
PPM and 375 PPM. You may want to
Respirator selection example. Let’s consider selecting a respirator with an
assume: APF higher than 10 for that reason.
• Your employees are working with a Reference Table 1 of T8CCR, section
solvent that has a PEL of 35 PPM 5144(d)(3) for a listing of the APFs
averaged over an 8-hour period, as corresponding to the different types of
well as a STEL of 70 PPM averaged respirators.
over a 15-minute period.
• You have determined that employees’ Full-face air-purifying respirators (non-
8-hour average exposures range from PAPR) have an APF of 50, but that
225 to 335 PPM, depending on the APF is only applicable if a passing
work employees are engaged in. quantitative fit test is performed. An
• It was also determined that there APF of 10 must be used instead if the
are certain steps in the work user undergoes a passing qualitative
process where some employees can fit test. See Fit testing of Tight-fitting
experience exposures ranging from Respirators (page 15) for more
550 to 850 PPM for short periods of information.
time.
• The respirator being considered has an Comfort, visibility, and communication
APF of 10.
• Certain models or types of respirators
Is this respirator adequate? (e.g., half-face vs. full-face) may be more
uncomfortable to wear or cumbersome to
The 8-hour average exposure tops out use than others.
at 335 PPM, which is less than the MUC • Respirators must not create a hazard by
of 350 PPM (PELx10) – so yes, it is impairing the worker’s vision, hearing, or
adequate relative to the PEL. But...the communication. Some models or types
short-term exposures top out at 850 PPM of respirators impair visibility more than
and the corresponding MUC is 700 PPM others, and some allow for better verbal
(STELx10), which means a respirator with communication. Certain PAPRs and
a higher protection factor will be needed. atmosphere-supplying respirators can
introduce air noise that may make it more
Note that each of the airborne difficult for the user to hear.
contaminant sampling methods have
assigned sampling and analytical Heat and physical stress
errors (SAE). Be sure to keep this in
mind when determining if your employees’ • The physical stress of wearing a
exposures exceed an assigned PEL, respirator may aggravate underlying
STEL, or Ceiling. For instance, in the acute or chronic diseases, particularly
example above, the 8-hour exposures diseases related to the heart and lungs.
were determined to top out at 335 PPM, • Use of atmosphere-supplying respirators
which is only 15 PPM less than the MUC in lieu of air-purifying respirators can
13result in less heat load, and in some cases • Section 5197, Occupational Exposure to
the cooling of the air being supplied to the Food Flavorings Containing Diacetyl
user. • Section 5198, Lead
• Some of the hazardous substances listed
Comfort, visibility, communication, heat and in article 110, Regulated Carcinogens
physical stress are some of the reasons • Some of the hazardous substances listed
section 5144(d)(1)(D) requires employers to in article 4, Dusts, Fumes, Mists, Vapors,
select respirators from a sufficient number and Gases
of respirator models and sizes so that the
respirator is acceptable to and correctly fits The manufacturer of the respirator you are
the user. considering should be able to assist you with
proper selection. Be sure to also always refer
PAPRs to the respirator instructions provided by the
manufacturer. Other resources for proper
• If the physician or other respirator selection are:
licensed health care
professional (PLHCP) • NIOSH Guide to the Selection and Use of
conducting the employee’s Particulate Respirators
medical evaluation finds • NIOSH Respirator Selection Logic
a medical condition
that may place the Medical Evaluations
employee’s health at
increased risk if a negative Using a respirator may place a physiological
pressure respirator is burden on employees that varies with the:
used, the employer must
provide a PAPR if the • Type of respirator worn (certain types of
PLHCP’s medical respirators impose a greater physiological
evaluation finds that the employee can use burden than others).
such a respirator. • Job and workplace conditions in which the
• Several of the substance-specific respirator is used (e.g., heat load, level of
standards—such as asbestos (sections physical activity).
1529 or 5208), cadmium (section 1532 • Medical status of the employee (e.g.,
or 5207), and lead (section 1532.1 or preexisting lung or heart disorders,
5198)—require the provision of PAPRs claustrophobia).
over regular APRs if an employee prefers
to use a PAPR and it will provide sufficient This is why all employees required to use
protection. respirators must be medically evaluated to make
sure they are able to wear them.
Other Cal/OSHA hazardous substance-
specific regulations that can influence Medical approval is also required for employees
your respirator selection: voluntarily using reusable elastomeric respirators.
Voluntary use of filtering facepiece respirators is
• Section 5150, Ventilation and Personal the only time medical approval is not required.
Protective Equipment Requirements for
Welding, Brazing and Cutting What needs to be done when setting up
• Section 5152, Ventilation and Personal respirator medical evaluations for your
Protective Equipment Requirements employees:
for Grinding, Polishing, and Buffing
Operations • Identify a physician or other licensed health
14care professional (PLHCP) to perform the use (including its use for rescue and escape).
medical evaluations. • The expected physical work effort.
• Ensure that a medical questionnaire, or an • The additional protective clothing and
initial medical examination that obtains the equipment to be worn.
same information as required by section • The temperature and humidity extremes that
5144, Appendix C - Part A, sections 1 and may be encountered.
2, is used. The questions in Part B, or other • A copy of the written respiratory protection
questions not listed, can be included at the program.
discretion of the PLHCP who will review the • A copy of T8CCR, section 5144.
questionnaire.
• Ensure that the medical evaluations are Additional medical evaluations are required
administered confidentially during the when:
employee’s normal working hours or at a time
and a place convenient to the employee. • An employee reports medical signs or
• Ensure medical evaluations are performed symptoms that are related to their ability to
before the employee is fit tested or required to use a respirator.
use the respirator in the workplace for the first • A PLHCP, supervisor, or the respirator
time. program administrator indicates an employee
• Provide the employee with an opportunity to needs to be reevaluated.
discuss the questionnaire and the evaluation • Information from the respiratory protection
results with the PLHCP. program, including observations made during
• Obtain a written recommendation from the fit testing and program evaluation, indicates a
PLHCP regarding an employee’s ability to need for employee reevaluation.
use a respirator that is limited to the following • A change occurs in workplace conditions
information: (e.g., physical work effort, protective clothing,
□ Any limitations on respirator use related temperature) that may result in a substantial
to the medical condition of the employee increase in the physiological burden placed
or related to the workplace conditions on an employee.
in which the respirator will be used and
whether the employee is medically able to Fit Testing of Tight-fitting Respirators
use the respirator.
□ The need, if any, for follow-up medical Why do tight-fitting respirators have to be
evaluations. fit tested?
□ A statement that the PLHCP has provided
the employee with a copy of the PLHCP’s Faces come in a wide variety of shapes
written recommendation. and sizes. When it comes to tight-fitting
respirators, this means a particular respirator
You must provide your employees with make, model and size may fit one person,
instructions on delivering or sending the but not another. Any leakage between
completed questionnaire directly to the the user’s face and respirator facepiece
PLHCP who will review it in order to ensure seal means the user may not be properly
that employees’ medical evaluations remain protected.
confidential.
The purpose of fit testing is to identify
Information that must be given to the PLHCP the specific make, model, style and size
includes: of the tight-fitting respirator that is best
suited for each employee. In addition, fit
• The type and weight of the respirator. testing provides an opportunity to check for
• The duration and frequency of the respirator’s
15problems with respirator use and reinforces a person’s response to a test agent that
respirator training by giving employees an they can taste, smell or perceive due to
opportunity to review the proper methods for lung/nasal irritation.
putting on and wearing the respirator.
Tight-fitting, negative pressure
The following are some issues you need to APRs. Whether half or full-face, the
consider when developing your fit testing maximum APF that can be applied
procedures is 10 when a qualitative fit test is
performed. A passing quantitative fit
Fit testing is required: test would have to be achieved for a
full-face respirator in order to apply an
• Before the initial use of a respirator in the APF of 50, or greater.
workplace.
• Whenever a different respirator facepiece Quantitative fit test
is used. (QNFT) is more objective
• At least annually. and assesses the adequacy
• Whenever the employee reports changes of a respirator’s fit by
or whenever the employer, respirator measuring the amount of
program administrator or PLHCP observes leakage into the respirator.
changes in the employee’s physical The result produced by a
condition that could affect respirator fit QNFT is expressed as a fit factor, which
(e.g., facial scarring, dental changes, is a quantitative estimate of the fit of a
cosmetic surgery or an obvious change in particular respirator to a specific individual.
body weight).
Minimum passing average fit factor
○ The employee must be given a
reasonable opportunity to select a ○ 100 for half-face tight-fitting,
different respirator facepiece and to be negative pressure respirators.
retested, if the employee subsequently ○ 500 for full-face tight-fitting
indicates that the fit of the respirator is respirators.
unacceptable.
○ Employees cannot have facial hair that Reference Table 1 of section 5144 for a
interferes with the face-to-facepiece breakdown of the different types of respirators
seal during the fit testing procedures, and their APF.
or at any time they are required to wear
respirators. Tight-fitting atmosphere-supplying and
powered air-purifying respirators.
How are respirators fit tested?
Fit testing is accomplished by performing
Employees using a negative or a positive- QNFT or QLFT only in the negative
pressure, tight-fitting facepiece respirator pressure mode – regardless of the
must be provided with either a qualitative or mode of operation (positive or negative-
a quantitative fit test administered using one pressure) actually used in the workplace.
of the protocols detailed in section 5144, This can be done in a couple of ways:
Appendix A, Fit Testing Procedures.
1. QLFT: Temporarily convert the
Qualitative fit test (QLFT) is a subjective respirator user’s actual facepiece
pass/fail test that is used to assess the into a negative pressure respirator
adequacy of a respirator’s fit by relying on with appropriate filters, or by using an
16identical negative-pressure air-purifying Positive and negative-pressure seal
respirator facepiece with the same checks
sealing surfaces as a surrogate for the
atmosphere-supplying or powered air- Employees must perform a
purifying respirator facepiece. positive-pressure and/or a
2. QNFT: Modify the facepiece to allow negative-pressure seal check
sampling inside the facepiece, midway each time they put on a tight-
between the nose and mouth. This fitting respirator by using either
must be accomplished by installing one of the following:
a permanent sampling probe onto
a surrogate facepiece, or by using • The procedures provided in T8 CCR,
a sampling adapter designed to Section 5144, Appendix B-1, User Seal
temporarily provide a means of Check Procedures.
sampling air from inside the facepiece. • The manufacturer’s procedures that the
employer demonstrates are as effective.
Prescription eyeglasses and personal
protective equipment, such as ear muffs, End-of-life service indicators (ESLI) and
safety glasses or face shields, can interfere cartridge/canister change-out schedules
with the fit and function of a respirator (and
vice versa), so be sure to have employees The service life of a cartridge/canister
wear the eyeglasses and personal protective depends on many factors, including
equipment they’ll be using along with the environmental conditions (e.g., high
respirator being fit tested. humidity), breathing rate, cartridge capacity,
the amount of contaminant in the air and
Proper Respirator Use how many hours the cartridge is used each
day. Not changing out cartridges/canisters as
You need to be aware of, and develop needed can mean employees may be over-
procedures designed to prevent situations exposed to the contaminants of concern.
that can compromise the effective use of You cannot always rely upon your senses
respirators and jeopardize workers’ protection, to detect cartridge/canister saturation and
such as: breakthrough.
• The person wearing the respirator fails to ESLI: Some cartridges and canisters are
properly perform seal checks. equipped with an ESLI that warns the user of
• The person wearing the respirator is also the end of adequate respiratory protection.
using personal protective equipment, The indicator is usually a sorbent material
prescription eyeglasses or other that changes color when the cartridge/
equipment that interferes with the face-to- canister approaches saturation or is no
facepiece seal. longer effective. However, few cartridges/
• The respirator is not properly repaired, and canisters are currently equipped with an
its defective parts are not replaced. ESLI.
• Modifications are made to the respirator, or
non-approved replacement parts are used. Cartridge change-out schedules: Most
• Filters/cartridges are not being changed employers will have to develop a cartridge
out as required. or canister change schedule or provide
• The person has facial hair or there are employees with atmosphere-supplying
other conditions that interfere with the respirators. A change schedule is the part
face-to-facepiece seal or valve function. of your respiratory protection program that
17determines how often cartridges/canisters PAPRs
must be replaced, and which information was
relied on to make this determination. The battery of a PAPR is a critically
important component. Be sure to follow the
You must base your change schedule on: manufacturer’s instructions on proper use,
care, maintenance, and charging.
• The results of exposure assessments
relevant to your specific workplace. Identification of filters, cartridges, and
• The respirator manufacturer’s cartridge canisters
capacity data, or other reliable data.
• The workplace environmental conditions Ensure that:
(e.g., temperature, humidity).
• All filters, cartridges and canisters used
How to create a cartridge/canister change-out in the workplace are labeled and color-
schedule: coded with the NIOSH approval label.
• The label is not removed and remains
• Use a math model, such as what’s legible.
provided on the Fed OSHA Respirator
Etool or the NIOSH MultiVapor Continuing respirator effectiveness
Application.
• Use the manufacturer’s • Appropriate surveillance must be
recommendations. Most of the respirator maintained of work area conditions and
manufacturers have produced their own degree of employee exposure or stress.
mathematical models that can be used for You need to reevaluate the continued
their own respirators. effectiveness of the respirator program
(refer to Program Effectiveness
Be sure to take notice of the instructions Evaluation (page 22) for additional
and limitations for each of the models. You guidance) when there is a change in work
should use a conservative estimate when area conditions or degree of employee
establishing the change schedule. exposure or stress that may affect
respirator effectiveness.
For particulate filters, it’s important • Ensure that employees leave the
employees understand that they need to respirator use area:
change out filters when they start to notice □ To wash their faces and respirator
increased difficulty breathing through the facepieces as necessary to prevent
filters. eye or skin irritation associated with
respirator use.
Other Cal/OSHA hazard-specific □ If they detect vapor or gas
regulations that can influence your breakthrough, changes in breathing
change-out schedules resistance or leakage of the facepiece.
□ To replace the respirator or the filter,
• Some of the hazardous substances listed cartridge or canister elements.
in article 110, Regulated Carcinogens. • Replace or repair the respirator before
• Some of the hazardous substances allowing an employee to return to the work
listed in article 4, Dusts, Fumes, Mists, area if the employee detects vapor or
Vapors, and Gases. gas breakthrough, changes in breathing
resistance or leakage of the facepiece.
18• Proper storage. Respirators must be
Also look at: protected from:
○ Section 5144 (d) and (g) for more detail on □ Damage and deformation
using respirators in routine or reasonably □ Contamination
foreseeable emergency situations, □ Dust
interior structural firefighting and IDLH □ Sunlight
atmospheres. □ Extreme temperatures
○ Section 5192(q) Emergency Response to □ Excessive moisture
Hazardous Substance Releases where □ Damaging chemicals
employees are engaged in emergency
response. Emergency respirator storage:
○ Needs to be readily accessible to the
Maintenance and Care of Respirators work area.
○ Have clearly marked compartments or
You are required to provide each respirator covers.
user with a respirator that is clean, sanitary ○ Follow the manufacturer’s
and in good working order. This involves recommendations.
establishing procedures and schedules for the
cleaning and disinfecting, storage, inspection • Inspections:
and repair of respirators. At a minimum, the □ Be sure to include checks for:
maintenance program must include policies ■ Respirator function
and procedures on: ■ Tightness of connections
■ Condition of parts, including:
• Cleaning and disinfecting. Ensure that ○ The facepiece
either of the following are implemented: ○ Head straps
□ The procedures for cleaning and ○ Valves
disinfecting respirators described ○ Connecting tubes
in section 5144, Appendix B-2, ■ Pliability of elastomeric parts and
Respirator Cleaning Procedures. signs of deterioration.
□ The procedures recommended by the ■ Cartridges, canisters or filters.
respirator manufacturer, provided that □ Respirators that are found to be
such procedures are of equivalent defective must be removed from
effectiveness. service and discarded or repaired.
□ SCBAs:
Clean and disinfect respirators at the ■ Air and oxygen cylinders
following intervals: maintained in a fully charged state,
and recharged when pressure
■ Exclusive-use respirators–as often falls to 90% of the manufacturer’s
as necessary to maintain a sanitary recommended pressure level.
condition. ■ Proper function of the regulator
■ Shared respirators–before being and warning devices.
worn by different persons. □ Emergency use respirators:
■ Emergency-use respirators–after ■ Certify the respirator by
each use. documenting the date the
■ Respirators used in fit testing and inspection was performed, the
training–after each use. name (or signature) of the person
who made the inspection, the
findings, required remedial action
19and a serial number or other apparatus must meet the requirements for
means of identifying the inspected Grade D breathing air (ANSI/ Compressed
respirator. Gas Association’s publication Commodity
■ Provide this information on a Specification for Air, G-7.1), which includes:
tag or label that is attached to
the storage compartment for the • Oxygen content of 19.5% to 23.5%.
respirator, is kept with the respirator • Hydrocarbon (condensed) content of 5
or is included in inspection reports milligrams per cubic meter of air or less.
stored as paper or electronic • Carbon monoxide (CO) content of 10
files. This information must be parts per million (ppm) or less.
maintained until replaced following • Carbon dioxide content of 1,000 ppm or
a subsequent certification. less.
• Lack of noticeable odor.
Inspect respirators at the following
intervals: Refer to section 5144(i) requirements if your
workplace uses liquid or compressed oxygen
■ All respirators used in routine at greater than 23.5%.
situations - before each use and
during cleaning. Compressed air cylinders
■ Emergency use respirators - at least
monthly, in accordance with the Ensure cylinders used to supply breathing air
manufacturer’s recommendations, to respirators:
and before and after each use.
■ Emergency escape-only respirators • Are tested and maintained as prescribed
- before being carried into the in the Shipping Container Specification
workplace for use. Regulations of the Department of
■ SCBA - monthly. Transportation.
• Have a certificate of analysis from the
• Repairs: supplier that the breathing air meets the
□ Only done by persons appropriately requirements for Grade D breathing air.
trained to perform such operations, • Have a moisture content that does not
and only using the respirator exceed a dew point of -50 deg. F at 1
manufacturer’s NIOSH-approved parts atmosphere pressure.
designed for the respirator. • Are only from the respirator manufacturers
□ Only according to the manufacturer’s that obtained the NIOSH approval, and are
recommendations and specifications. marked and maintained in accordance with
□ Reducing and admission valves, the NIOSH respirator certification for the
regulators and alarms are only SCBA.
adjusted or repaired by the
manufacturer or a technician trained Compressors
by the manufacturer.
Ensure that the compressors used to provide
Breathing Air Quality and Supply breathing air are constructed and situated to:
Quality • Prevent entry of contaminated air into the
air-supply system (e.g., vehicular traffic,
The compressed breathing air provided discharge from other ventilation systems).
to airline or self-contained breathing • Minimize moisture content so that the
20dew point at 1 atmosphere pressure is 10 down or reduction below minimal
degrees F below the ambient temperature. operating parameters, or excessive air
• Have suitable in-line air-purifying sorbent contamination), as well as the alarm
beds and filters to ensure breathing trigger levels (e.g., greater than 10 PPM
air quality. Sorbent beds and filters are of carbon monoxide).
maintained and replaced following the • Pressure vessel inspections and
manufacturer’s instructions. permits. Airline respirator compressors
□ Have a tag at the compressor may have a receiver large enough to fall
containing the most recent change under T8CCR, subchapter 1, Unfired
date and the signature of the person Pressure Vessel Orders requirements.
authorized by the employer to perform • Sufficient capacity to accommodate
the change. the type of respirator, number of users,
• Have high-temperature and/or carbon lengths of airline hose and any in-line
monoxide alarms to monitor carbon devices that may be used.
monoxide levels on oil-lubricated □ The type of airline respirator being
compressors. The air supply must be used. For example, a continuous
monitored at intervals sufficient to prevent flow respirator may require a
carbon monoxide in the breathing air from higher quantity of air suppled to the
exceeding 10 ppm if only high-temperature facepiece/helmet/hood compared
alarms are used. to a demand or pressure demand
• Ensure breathing air couplings are respirator.
incompatible with outlets for non-respirable □ Number of users at one time. The
worksite air or other gas systems. larger the number of users, the higher
• Ensure no asphyxiating substance is the capacity requirements of the air
introduced into breathing air lines. source.
□ Length of airline hose used.
Airline systems Typically, the longer the length,
the higher the required operating
A typical airline system consists of several pressure (P.S.I.) at the airline
components. The following summarizes what connection point. At the same time,
some of those components are and some never exceed the maximum length
additional issues that need to be addressed in of airline or air pressure at the airline
order to ensure that the system will be safe for connection point, as indicated by the
the users, and comply with section 5144. manufacturer.
□ In-line devices. Depending on the
The air source, which typically consists respirator manufacturer and model,
of an air compressor or tanks/cylinders of there are devices that can be used to
compressed air, and the airlines used to heat or cool (e.g., an air vortex tube)
distribute the air to the users. the air being provided from the airline
to the facepiece. Use of such devices
• Maintenance and calibration of air may require higher air supply capacity.
monitoring systems. When a carbon
monoxide sensor is required, it is The respirator assembly.
important that it is maintained and
calibrated according to the manufacturer’s NIOSH approval is granted to respiratory
instructions. This will include the alarm protection equipment made up of specific
system that alerts the users of an air combinations of parts or assemblies
supply failure (e.g., a complete shut-
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