Key Elements of a

Sound Respiratory Protection Program

Because every life has a purpose...

 Key Elements of a Sound Respiratory Protection Program

The fundamental goal of any respiratory protection program is to control occupational

diseases caused by breathing air contaminated with harmful dusts, fogs, fumes, mists, gases,
smokes, sprays, and/or vapors. The defense against these contaminants is simple: Keep them
out of the air that workers breathe. Always implement engineering and/or administrative
controls first. If contaminants still present a hazard, you must provide appropriate respiratory

Contents protection for every employee who might be exposed to them.

MSA can help you take a comprehensive approach to sound Respiratory Protection practices.
This guide will help you understand the need for respirators, how they work, and what their
The 7 Key Elements limitations are.
1. A Written Respiratory OSHA (the Occupational Safety and Health Administration) and NIOSH (the National Institute
Protection Program of Occupational Safety and Health) regulations define all the specific requirements which
Administration must be followed, including the capabilities of appropriate respiratory protection.
Voluntary Respirator Use
Employers must follow the requirements of these governmental regulations, both the
general regulations which apply to all workplaces and the specific regulations for exposures
Respiratory Hazards in their particular industry, such as lead, silica dust, asbestos, and ammonia.
2. Hazard Assessment
Exposure Monitoring

3. Hazard Control
4. Respirator Selection PremAire® Cadet Escape
Respirator shown here
Types of Respirators

5. Training
Fit Testing

6. Respirator Care
7. Medical Surveillance

Program Evaluation

Record Keeping
The 7 Key Elements
Chances are that you are already familiar with the need for and use of respirators in your workplace, but as with anything else, it doesn’t hurt to
review your current program against standard operating procedures governing the selection and use of respirators.
According to program details in OSHA’s Respiratory Protection Standard (29 CFR 1910.134), the seven key elements that every respiratory
protection program should contain are:

1 A written plan detailing how the program will be administered 5 An employee training program covering hazard recognition,
2 A complete assessment and knowledge of respiratory hazards that
the dangers associated with respiratory hazards, and proper care

6 Inspection, maintenance, and repair of respiratory protective

and use of respiratory protective equipment

3 Procedures and equipment to control respiratory hazards, including

will be encountered in the workplace

7 Medical surveillance of employees

the use of engineering controls and work practices designed to limit equipment

4 Guidelines for the proper selection of appropriate respiratory

or reduce employee exposures to such hazards

protective equipment

1 A Written Respiratory Protection Program

Administration If possible, one person should administer these procedures,
The first step in a respiratory protection program is to establish written to ensure consistent coordination and direction and optimum
standard operating procedures governing the selection and use of results. The actual respiratory protection program itself for each
respirators. Regular inspection and evaluation of the program will workplace depends upon many factors, and may require input
ensure its continued effectiveness. from specialists such as safety personnel, industrial hygienists,
health physicists and physicians.
According to OSHA, a written program will help employers, employees,
and compliance officers gauge the adequacy of a given program. Voluntary Respirator Use
When developing your written respiratory protection program, be sure An employer must provide respiratory protection for employees
to include the following elements, designated by 29 CFR Part 1910.134:
 Procedures for selecting respirators for use in the workplace
who ask for it or let employees use their own respiratory
protection, if such respirator use will not create a hazard.
 Fit-testing procedures for tight-fitting respirators Fit testing is not required for voluntary use.
(including a signed copy of employees’ fit-test records)
 Procedures for proper use of respirators in routine and emergency Respiratory Hazards
situations Before a respiratory protection program is initiated, it is important
 Procedures and schedules for cleaning, disinfecting, storing, to first understand the types of respiratory hazards inherent to 3
inspecting, and repairing respirators your industry. Of the three normally recognized ways toxic
 Procedures to ensure adequate air quality, quantity, and flow of materials can enter the body—through the (1) gastrointestinal
breathing air for atmosphere-supplying respirators tract, (2) skin, and (3) lungs—the respiratory system presents the
 Medical evaluations of employees required to wear respirators quickest and most direct avenue of entry. This is because of the
respiratory system’s direct relationship with the circulatory system
Employers must:
 Submit a written respiratory protection program unless the choice
and the constant need to oxygenate tissue cells to sustain life.
of voluntary respiratory protection is a filtering facepiece (dust The three basic classifications of respiratory hazards are:
mask) • oxygen-deficient air
 Provide voluntary respirator users with Appendix D of the Standard • particulate contaminants
 Ensure that employees using a respirator voluntarily have medical • gas and vapor contaminants
clearance

Employees must clean, store, and maintain the respirator so that its use
does not present a health hazard.

MSAsafety.com
Key Elements of a Sound Respiratory Protection Program

Oxygen Deficiency place in the upper respiratory tract. diffuse freely within an area or container.
Normal ambient air contains an oxygen However, with excessive “dust” exposures Nitrogen, chlorine, carbon monoxide, carbon
concentration of 20.8% by volume. When the or a diseased respiratory system, the dioxide, and sulfur dioxide are examples.
oxygen level dips below 19.5%, the air is efficiency of the cleansing action can be In terms of chemical characteristics, gaseous
considered oxygen-deficient. Oxygen significantly reduced. contaminants may be classified as follows:
concentrations below 16% are considered The various types of airborne particulate Inert Gases—These include such true gases
unsafe for human exposure because of contaminants can be classified as follows: as helium, argon, neon, etc. Although they do
harmful effects on bodily functions, mental
Fumes—An aerosol created when solid not metabolize in the body, these gases
processes, and coordination.
material is vaporized at high temperatures represent a hazard, because they can produce
It is important to note that life-supporting and then cooled. As it cools, it condenses into an oxygen deficiency by displacement of air.
oxygen can be further displaced by other extremely small particles—generally less than Acidic Gases—Often highly toxic, acidic
gases, such as carbon dioxide. When this 1 micron in diameter. Fumes can result from gases exist as acids or produce acids by
occurs, the result is often an atmosphere that operations such as welding, cutting, smelting, reaction with water. Sulfur dioxide, hydrogen
can be dangerous or fatal when inhaled. or casting molten metals. sulfide and hydrogen chloride
Oxygen deficiency also can be caused by rust,
Dusts—An aerosol consisting of are examples.
corrosion, fermentation, or other forms of
mechanically produced solid particles derived Alkaline Gases—These gases exist as alkalis
oxidation which consume oxygen. The impact
from the breaking up of larger particles. Dusts or produce alkalis by reaction with water.
of oxygen-deficiency can be gradual or
generally have a larger particle size when Ammonia and phosphine are two examples.
sudden.

compared to fumes. Operations such as
sanding, grinding, crushing, drilling, Vapors are the gaseous state of substances
machining, or sand blasting are the worst dust that are liquids or solids at room temperature.
Particulate Contaminants They are formed when the solid or liquid
producers. Dust particles are often found in
Particulate contaminants can be classified the harmful size range of 0.5 to 10 microns. evaporates.
according to their physical and chemical
Mists—An aerosol formed by liquids, which In terms of chemical characteristics, vaporous
characteristics and their physiological
are atomized and/or condensed. Mists can be contaminants may be classified as follows:
effect on the body. The particle diameter
in microns (1 micron = 1/25,400 inch) is created by such operations as spraying, Organic Compounds—Contaminants in
of utmost importance. Particulates below 10 plating, or boiling, and by mixing or cleaning this category can exist as true gases or vapors
microns in diameter have a greater chance to jobs. Particles are usually in the size range of produced from organic liquids. Gasoline,
enter the respiratory system, 5 to 100 microns. solvents, and paint thinners are examples.
and particles below 5 microns in diameter are  Organometallic Compounds—These are
more apt to reach the deep lung or alveolar generally comprised of metals attached to
spaces. Gas and Vapor Contaminants
organic groups. Tetraethyllead and organic
Gas and vapor contaminants can be classified
In healthy lungs, particles from 5 to 10 phosphates are examples.
according to their chemical characteristics.
microns in diameter are generally
removed from the respiratory system by True gaseous contaminants are similar to
a constant cleansing action that takes air in that they possess the same ability to

Advantage® 420 Respirator Advantage 200 LS Respirator Advantage 3200 Respirator

2 Hazard Assessment
Proper assessment of your specific hazard(s) is the first important step to
protection. This requires a thorough knowledge of processes, equipment, raw
materials, end-products, and by-products that can create an exposure hazard.
First, you must make an initial determination of workplace conditions. This simple
calculation of exposures does not require sampling of the environment. Factor in
workplace size, ventilation, the amount of the regulated substance present, the
type of operation, and the proximity of the workers to the source of emissions.
According to OSHA, personal exposure monitoring is the “gold standard” for
determining employee exposure. It is the most reliable approach for assessing the
level and type of respiratory protection required. Sampling which uses methods
appropriate for contaminants(s) should represent the worst-case exposures or
enough shifts and operations to determine the accurate range(s) of exposure.
To determine an atmosphere’s oxygen content or concentration levels of particulate
and/or gaseous contaminants, air samples must be taken with proper sampling
AirHawk® MMR SCBA
instruments during all conditions of operation. The sampling device and the type
and frequency of sampling (spot testing or continuous monitoring) will be dictated
by the exposure and operating conditions.
Breathing zone samples are recommended and sampling frequency should be
sufficient to assess the average exposure under the variable operating and
exposure conditions.
Should contaminant concentrations exceed exposure limits recommended by the
American Conference of Governmental Industrial Hygienists (ACGIH), OSHA, or
NIOSH, hazard control procedures must be implemented promptly.
The employer is required to evaluate respiratory hazards in the workplace, identify
relevant workplace and use factors, and base respirator selection on these factors.

Exposure Monitoring
Exposure monitoring plays a critical role in the respirator selection process.
The results from such testing will help you determine whether respiratory
protection is needed and, if it is, the type of respirator that is required. Generally,
respirator selection is based on three factors:
 The results of your atmospheric monitoring or sampling program
G1 PremAire Cadet Escape Respirator System

 The accepted ACGIH, OSHA, or NIOSH exposure limits for the substance(s)
5
present
 The maximum use concentration (of a substance) for which a respirator can
be used

3 Hazard Control
Hazard control should start at the process, equipment, and plant design levels
where contaminants can be controlled effectively at the outset. With operating
processes, the problem becomes more difficult. In all cases, however, attention
should be given to the use of effective engineering controls to eliminate and/or
reduce exposures to respiratory hazards. This includes consideration of process
encapsulation or isolation; use of less toxic materials in the process’ and suitable
exhaust ventilation, filters, and scrubbers to control the effluents.
Because it is sometimes not practical to maintain engineering controls that
eliminate all airborne concentrations of contaminants, proper respiratory protective OptimAir® TL Powered Air-Purifying Respirator
devices should be used whenever such protection is required.

MSAsafety.com
Key Elements of a Sound Respiratory Protection Program

OSHA’s Assigned Protection Factors Table

Loose-fitting
TYPE OF RESPIRATOR1, 2 Quarter mask Half mask Full facepiece Helmet/ hood facepiece

1. Air-Purifying Respirator 5 310 50

4
2. Powered Air-Purifying Respirator (PAPR) 50 1000 25/1,000 25

3. Supplied-Air Respirator (SAR) or Airline Respirator 10 50

• Demand mode 4
50 1,000 25/1,000 25
• Continuous flow mode
• Pressure-demand or other positive-pressure mode 50 1,000

4. Self-Contained Breathing Apparatus (SCBA)

• Demand mode 50 50
10
• Pressure-demand or other positive-pressure mode 10,000 10,000
(e.g., open/closed circuit)

Notes:
1 Employers may select respirators assigned for use in higher workplace concentrations of a hazardous substance for use at lower concentrations of that substance, or when
required respirator use is independent of concentration.
2 The assigned protection factors in Table 1 are only effective when the employer implements a continuing, effective respirator program as required by this section (29 CFR
1910.134), including training, fit testing, maintenance, and use requirements.
3 This APF category includes filtering facepieces, and half masks with elastomeric facepieces.

4 The employer must have evidence provided by the respirator manufacturer that testing of these respirators demonstrates performance at a level of protection of 1,000 or greater
to receive an APF of 1,000. This level of performance can best be demonstrated by performing a WPF or SWPF study or equivalent testing. Absent such testing, all other PAPRs and
SARs with helmets/hoods are to be treated as loose-fitting facepiece respirators, and receive an APF of 25.
5 These APFs do not apply to respirators used solely for escape. For escape respirators used in association with specific substances covered by 29 CFR 1910 subpart Z, employers
must refer to the appropriate substance-specific standards in that subpart. Escape respirators for other IDLH atmospheres are specified by 29 CFR 1910.134 (d)(2)(ii).

4 Respirator Selection
All respirators in use must be NIOSH-approved (NIOSH 42 CFR Part 84). Types of Respirators
Selecting respirators entails knowing what level of respiratory Respirators fall under two classifications: air-purifying and
protection employees need, as well as which size respirator is right for air-supplied. Air-purifying respirators are used against particulates,
any face and facial contours. gases, and vapors. These are categorized as negative-pressure
Respiratory protective devices vary in design, application, and respirators that use chemical cartridges and/or filters; gas masks;
protective capability. Thus, the user must assess the inhalation hazard and positive-pressure units such as powered air-purifying respirators
and understand the specific use limitations of available equipment to (PAPRs). Air-supplied devices rely on a primary air source to deliver a
assure proper selection. steady flow of respirable air to the user’s facepiece. These consist of
If your calculation shows that exposure concentrations exceed Self-Contained Breathing Apparatus (SCBA) and air-line devices.
recommended limits and engineering/administrative controls do not Air-Purifying Respirators (APRs) range from simple disposable cup
reduce exposure below the permissible limit, tailor your respiratory masks to low-maintenance half-mask facepieces with cartridges and/or
protection program to your specific conditions based on: filters to the more complex PAPRs with full- facepieces or hoods.
 Toxicity (TLV or TWA)  APRs for particulates use filters to capture dusts, mists, and
 Maximum Expected Concentration fumes. Filters do not protect against gases or vapors, and generally
 OSHA assigned protection factors become less effective as particles accumulate on the filter and plug
 Oxygen level spaces between the fibers. Some filtering APRs require filter
 IDLH concentration replacement when the user finds it difficult to breathe through
 Warning properties (adequate or not) them. Others should be changed after each shift.
 Sorbent limitations  Gas and vapor APRs employ chemical cartridges or canisters to
 Facepiece fit remove hazardous gases or vapors from the air. They do not protect
 Mobility requirements against airborne particles. Made to protect against specific gases or
 Type of use (routine, escape, or emergency entry) vapors, they provide protection only as long as the cartridge’s
absorbing capacity is not depleted.
The service life of a chemical cartridge  Air-Line Respirators are used for  Combination SARs are air-line devices
depends upon many factors and can be extended periods in non-IDLH used for extended work periods in
estimated in various ways. Cartridges and atmospheres. They use an air-line hose atmospheres that are or may be IDLH.
canisters require an end-of-service-life to deliver clean breathing air from a They have an auxiliary self-contained air
indicator (ESLI) or a change schedule, based stationary source of compressed air for cylinder that can be used if the primary
on objective information or data that will prolonged periods of time. Although air supply fails. The air cylinder can also be
ensure that canisters and cartridges are comparatively lightweight, air-line used for entry into or escape from IDLH
changed before the end of their useful life. In respirators can limit users’ mobility atmospheres, such as confined spaces.
the respirator program, the employer must because of the air-line hose that must Employers are required to provide employees
describe the information and data relied upon be attached. using SARs with breathing gases of high
and the basis for the canister and cartridge  Self-Contained Breathing Apparatus purity, and ensure that compressed air,
change schedule as well as the basis for (SCBA) have an open-circuit design that compressed oxygen, liquid air, and liquid
reliance on the data. provides air rated for 30 to 60 minutes. oxygen used for respiration is in accordance
 Combination APRs, fitted with both They consist of a wearable, clean-air with the specifications of OSHA Standard
particulate filters and gas/vapor cartridges, supply and a tight-fitting facepiece, and 1910.134(i).
are worn in atmospheres that contain are used for short-duration entrance or
hazards of both particulates and gases. escape from atmospheres that are or
Supplied-Air Respirators (SARs), may be IDLH. They offer relatively
comprise air-line respirators, SCBA, and unrestricted movement.
combination (supplied-air) respirators.

5 Training
For proper use of any respiratory protection device, it is essential that Fit Testing
the user be properly instructed in its selection, use, and maintenance. OSHA requires fit testing for any face mask (full or half) designed to have
Both supervisors and workers must be so instructed by competent a tight seal along the face, whether it is used in a positive- or negative-
persons. pressure mode, and whether it is disposable or not.
Minimum training must include: Qualitative fit test methods are subjective in nature and rely on the
 Methods of recognizing respiratory hazards judgment of the test subject. They are essentially a pass/fail fit test to
 Instruction in the hazards and an honest appraisal of what could assess the adequacy of respirator fit.
happen if the proper respiratory protection device is not used
 Explanation of why more positive control is not immediately
Quantitative testing methods rely on objective data to determine a
proper fit. An assessment of the adequacy of respirator fit is determined
feasible. This must include recognition that every reasonable effort by numerically measuring the amount of leakage into the respirator.
is first being made to reduce or eliminate the need for respiratory
protection If the required fit factor is greater than 100, i.e., when higher levels of
 A discussion of why various types of respiratory protection devices respiratory protection are needed, quantitative fit-testing must be
7
are suitable for particular purposes conducted. Most experts agree that quantitative fit-testing provides
 A discussion of the device’s capabilities and limitations the most accurate information, because it uses actual test data, rather
 Instruction and training in actual use of respiratory protection than depending on the respirator wearer’s sense of smell and taste
equipment, and definite and frequent supervision to assure that it (subjective responses).
continues to be properly used
 Classroom and field training to recognize and cope with emergency
OSHA requires these eight exercises for both qualitative and
quantitative fit testing:
situations
1 normal breathing
Before an employee may be required to use any respirator 2 deep breathing
with a negative- or positive-pressure tight-fitting facepiece, 3 head side to side
the employee must be fit tested with the same make, model, 4 head up and down
style, and size of respirator that will be used. 5 talking out loud
Training should provide personnel with an opportunity to handle the 6 grimacing (quantitative only)
device, have it fitted properly, test its face-to-facepiece seal, wear it in 7 bending
normal air for a long familiarity period, and, finally, wear it in a test 8 normal breathing
atmosphere. OSHA requires fit tests to ensure proper fit for workers
who use respirators.

MSAsafety.com
6 Respirator Care 7 Medical Surveillance
Proper inspection, maintenance, and repair of respiratory protective According to OSHA, “using a
equipment are mandatory to ensure success of any respiratory respirator may place a physiological
protection program. The goal is to maintain the equipment in a burden on employees that varies with
condition that provides the same effectiveness as it had when it was the type of respirator worn, the job
first manufactured. and workplace conditions in which
All equipment must be inspected before and after each use. the respirator is used, and the
A record of all inspections by date must be kept, with the results medical status of the employee.”
tabulated. It is important to follow the recommendations of the Employers must determine an
manufacturer precisely. employee’s ability to use a respirator.

All non-disposable respiratory protective equipment must be cleaned Workers should never be assigned to
and decontaminated after each use. Disposable respirators and any operation requiring respiratory
accessories should be discarded after each use, and replaced with protection until a physician has
identical new respirators. determined that they are capable—
physically and psychologically—
Replacement of other than disposable parts must be done only by to perform the work using the
personnel with adequate training to ensure that the equipment is respiratory protective equipment.
functioning properly after the work is accomplished. Only parts
supplied by the manufacturer for the product being repaired must
be used.

Program Evaluation Record Keeping

Employers are required to conduct periodic evaluations of the Employers must retain written information regarding medical
workplace to ensure that the written respiratory protection program evaluations, fit testing, and the respirator program. This information
is being properly implemented, and to consult employees to ensure will facilitate employee involvement in the respirator program, assist
that they are using the respirators properly. The employer must the employer in auditing the adequacy of the program, and provide a
regularly consult employees required to use respirators to assess the record for compliance determinations by OSHA.
employees’ views on program effectiveness and to identify any
Records must be kept on:
 Medical evaluation
problems. Any problems that are identified during this assessment
must be corrected.
 Qualitative and Quantitative Fit Tests, which are retained until the
Factors to be assessed include, but are not limited to: next fit test is administered
 Respirator fit (including the ability to use the respirator without  Employee identity
interfering with effective workplace performance)  Make, model, style, and size of respirator tested
 Appropriate respirator selection for the hazards to which the  Date of test
 Results
employee is exposed
 Proper respirator use under the workplace conditions the employee
 Written copy of the current respirator program
encounters
 Proper respirator maintenance Although instituting a sound respiratory protection program will take
effort and financial investment, the objective of a such a program is
sound—ensuring that every worker is protected against potentially
fatal diseases.
Important
This document is intended to help employers understand the
respiratory protection requirements of OSHA and NIOSH government
standards, and is not intended to be the sole guide for complying with
29 CFR Part 1920.134 (OSHA) and 42 CFR Part 84 (NIOSH).
These government documents may be found in their entirety at
www.osha.gov

Note: This Bulletin contains only a general MSA – The Safety Company
description of the products shown. While uses 1000 Cranberry Woods Drive
and performance capabilities are described, Cranberry Township, PA 16066 USA
under no circumstances shall the products be Phone 724-776-8600
used by untrained or unqualified individuals www.MSAsafety.com
and not until the product instructions U.S. Customer Service Center
including any warnings or cautions provided Phone 1-800-MSA-2222
have been thoroughly read and understood. Fax 1-800-967-0398
Only they contain the complete
MSA Canada
and detailed information Phone 1-800-672-2222
concerning proper use and Fax 1-800-967-0398
care of these products.
MSA Mexico
Phone 01 800 672 7222
ID 1000-61-MC / February 2016
© MSA 2016 Printed in U.S.A.
Fax 52 - 44 2227 3943 MSAsafety.com