Respiratory Protection Program

Program Manual

The full manual for the OSU Respiratory Protection Program can be found using the following link:

OSU Respiratory Protection Program Manual

Hierarchy of Controls

In the field of occupational health and safety, the hierarchy of controls approach is commonly used to determine the best course of action for mitigating respiratory hazards. The end solution for managing respiratory hazards is often comprised of a combination of these controls:

1. Eliminating the respiratory hazard by stopping the hazardous activity.
2. Substituting the respiratory hazard by using a less hazardous material or process
3. Engineering controls for respiratory protection are varied and range from fume hoods to local exhaust systems.
4. Administrative controls for respiratory protection involve reassessing the task or using signage to warn of respiratory hazards in the area.
5. Personal protective equipment (PPE) such as N95 masks, half-face respirators, full-face respirators, and PAPRs serve as a last line of defense.

EH&S can provide a work site evaluation to determine what controls are feasible and what type of PPE, if applicable, is recommended.  

Employee Training

SciShield Respiratory Protection Training 

Respiratory Protection Training will be administered through SciShield. This training is automatically assigned when a respirator-related training requirement is assigned to an employee through the Manage Job Activities tab. The training is also located under the SciShield path of Training > Course Directory > Occupational Health and Safety. This is an annual requirement along with fit testing.

This training module helps identifies the purpose of using a respiratory and describes how respirators are used, including fit testing, inspection, seal checks, and maintenance and storage requirements. The goal of this lesson is to teach workers the purpose of respirators, the factors that influence respirator effectiveness, and the limitations and capabilities of different types of respirators. Workers will learn the employer's responsibilities for respirator use in the workplace, the preparations required before respirators are to be used, and their maintenance and storage requirements.

Supervisors are encouraged to provide additional training on the specific equipment or work environment as appropriate for their employees. If this route is taken, consult with Environmental Health and Safety prior to administering such training.

In-Person Training

During Respirator Fit Testing, the instructor will provide in-person training on the specific respirator that the employee is fitted for. This includes cartridge care, respirator care and storage, respirator and cartridge lifespans, pre-use respirator seal checks, fit testing, and general program requirements.

Fit Testing

What to bring / Prerequisites 

Individuals planning on attending a fit test session should bring any respirator or cartridge they have already been assigned to if they wish to be fit tested with that PPE. Otherwise, EH&S will use our set of respirators for fit testing and assign a size/model accordingly. 
For fit testing, it is required that individuals shave according to the guidelines set forth by the CDC. The primary rule is that no facial hair may pass over the seal of the respirator. Voluntary respirator users do not have to adhere to these guidelines, although they must be informed of the risks that are posed by having facial hair that crosses the seal of the respirator.

Fit Testing Protocol

1. The instructor connects one modified P100 cartridge and one normal P100 cartridge to the respirator and fits the clear tube to the modified cartridge. The respirator user dons and wears the respirator for several minutes before fit tests begins. For comfort, a clip is provided on the tubing to attach to the shirt of the user. This, along with standing closer to the PortaCount machine, prevents any tugging on the mask during the fit test.  
   • For N95 respirators, the fit testing probe kit is used to insert a probe into the fabric of the N95 mask. Make sure it is slightly off to the side, but not too far off – this may lead to suction on the user’s cheek
2. The user performs positive and negative pressure seal check (on HF and FF masks).
   • Positive – test subject exhales and places hand over air exhalation valve
   • Negative – test subject inhales while placing both hands over the inhalation cartridges 
3. These checks should result in very little to no air escaping from respirator.  If there is air escaping, re-adjust the respirator and re-tighten the straps to achieve an air-tight seal, or attempt again using a different sized respirator. If there is any doubt about sizing, use the “Fit Check” functionality for a real time check of the fit.
4. The instructor will begin the test on the PortaCount and the user will perform the following exercises: 
   • Bending Over (50 seconds) – The test subject shall bend at the waist as if he/she were to touch his/her toes, pause in the down position briefly, take 2 breaths, and stand up again.  Repeat for duration of activity.  
   • Jogging in Place (30 seconds) – Applies to HF and FF.  The test subject should lift knees and pump arms during this test. 
     1. For N95 Respirators, jogging in place is replaced with Reading of the Rainbow Passage. The test subject should read loud enough to be heard clearly by the test conductor.wn position briefly, take 2 breaths, and stand up again.  Repeat for duration of activity.  
   • Head Side to Side (30 seconds) – Standing in place, the subject should slowly turn his/her head from side to side.  Pause when the head is at each side, take 2 breaths each time.
   • Head Up and Down (30 seconds) – Standing in place, the subject should slowly move his/her head up and down.  The subject should inhale in the when looking up towards the ceiling. 
5. Once testing of a full or half face respirator is complete, give the user an alcohol wipe to allow them to clean up their respirator.  Remind them to avoid any harsh chemicals on the respirators, as it will break down the rubber seal over time.
6. Instructor should remind the user to store the respirator in a clean, dry space.  Storing respirators in a freezer zip lock bag can accomplish this.  We have these available for them to take.
7. Each subject’s information should be added to the “Respirator Mask Fit” white Binder for record keeping.  Notate the Maximum Fit Factor from the testing and all other pertinent details. This will serve as our paper (backup) documentation. Fit test results are also stored on the TSI PortaCount app and can be exported to an Excel document. 
8.  Record completion of Fit Testing in SciShield by following this process: 
   • Click “Training”
   • Click “Course Directory”
   • Click “Respirator Fit Test” (located under Occupational Health and Safety)
   • Click “Add a Record”
   • Search their name and ensure the date is correct
   • Click “Submit”

Annual Fit Test Requirement

Fit testing is an annual requirement for mandatory respirator users. SciShield will send alerts to the employee and their supervisor when this requirement is overdue. It is the responsibility of the employee and the supervisor to work with EH&S to ensure that this requirement is satisfied in a timely manner.

APFs, PELs and MUCs

Assigned Protection Factors (APFs)

The Assigned Protection Factor (APF) is the workplace level of respiratory protection that a respirator or class of respirators is expected to provide to employees given that they are enrolled in a continuing, effective respiratory protection program in compliance with 29 CFR 1910.134. APFs are used by OSU EH&S to select respirators with the proper level of protection for the airborne hazard exposure. The APF remains the same regardless of the nature of the exposure (particulate, gas, or vapor).

Permissible Exposure Limits (PELs)

The Permissible Exposure Limit (PEL) is the maximum concentration of a chemical or physical hazard a worker can be exposed to over a given period. Many substances have PELs that are calculated as a time-weighted average (TWA) over an eight-hour period, representative of the average workday. This means the exposure can fluctuate throughout the day so long as the average concentration does not exceed the PEL. Some substances also have a short-term exposure limit (STELs), which is the maximum concentration allowed for a short period of 15 minutes, and a ceiling limit that must not be exceeded at any time during a workday. A list of these values for recognized hazardous airborne contaminants can be found in the OSHA Permissible Exposure Limits – Annotated Tables.

For certain substances such as lead and silica, an action level is set below the PEL to trigger certain requirements. These include medical surveillance for signs of exposure to the substance and occupational exposure monitoring.

Maximum Use Concentrations (MUCs)

The Maximum Use Concentration (MUC) is the maximum atmospheric concentration of a hazardous substance from which an employee can be expected to be protected when wearing a respirator. This is determined by the APF of the respirator or class of respirators and the PEL of the hazardous substance. The MUC usually can be determined by multiplying the APF of the respirator by the PEL, STEL, ceiling limit, peak limit, or any other exposure limit used for the hazardous substance.

Whenever an exposure approaches the MUC or can be expected to do so, OSU EHS will select a more protective class of respirators for employees. MUCs cannot be applied to conditions that are immediately dangerous to life or health (IDLH). When the calculated MUC exceeds the IDLH level for a hazardous substance, or the performance limits of the cartridge or canister, then the maximum MUC will be set at that lower limit.

Exposure Monitoring

If you are performing work that involves exposure to substance(s) listed in the OSHA PEL tables, please contact your Department Safety Manager and the OSU EH&S Occupational Safety Manager to coordinate occupational exposure monitoring for your work environment. 

Respirator Maintenance

Cleaning

1. Remove all covering assemblies before cleaning and disinfecting:
   • Filters, cartridges, canisters
   • Speaking diaphragms
   • Demand and pressure-demand valve assemblies
   • Head band
   • Any other components recommended by the respirator manufacturer
2. Wash respirator and appropriate covering assemblies as recommended by the manufacturer in warm cleaner and disinfectant solution (49^oC/120^oF maximum). A recommended disinfecting solution can be made from ordinary household bleach diluted 1:10 with clear water, and the respirator/assemblies should be immersed for around two minutes.
   • A soft cloth may be used to help remove dirt or other foreign material.
   • Shake respirator as needed to remove water residues and any foreign material.
3. Inspect parts and replace any parts found defective.
4. Set respirator aside to air dry.
5. When dry, reassemble respirator and visually inspect / test parts and respirator assemblies for proper functionality.
6. Store respirator in sealed, clean, sanitary container (zip-lock bag), away from any source of contaminants. Respirators should not be hung by straps.
7. The face-piece, inhalation and exhalation valves must be in a normal position so as to prevent the abnormal "set" of elastomer parts during storage.

Inspections

Respirators should be inspected prior to and following use each time they are used. Employees should inspect the straps for wear and tear, make sure the respirator is clean on the inside and the outside, and ensure nothing on the respirator is broken or compromised.

Additionally, PAPR systems must be inspected with each use to ensure:

1. Sufficient battery charge
2. Proper airflow through the blower/tube – performed using the ball-in-tube tool
3. Backflow sensor function – performed by blocking airflow tube for 10-15 seconds and listening for the backflow alert
4. Cleanliness

Storage

Respirators should be stored in a cool dry area away from direct sunlight. The best storage apparatus for a personal respirator is either an air-tight plastic container or a zip-lock bag. The container should have the employee’s name written in an obvious location – this prevents it from getting mixed up with another employee’s PPE.

Cartridge Care

Cartridge use should be tracked to determine a replacement schedule that aligns with the cartridge usage. Tracking should include the user’s name, date of removal from package, and usage times/dates. The date should also be written on the side of the cartridge in permanent marker. Cartridges should be stored along with the respirator in a plastic zip-lock bag or sealed container. These two should only be stored together when completely dry to avoid moisture from entering the cartridge. 

Replacing P100 and other types of cartridges depends on storage conditions, exposure concentration, temperature, humidity, and breathing rate. Optimal cartridge care involves routine inspections for cracks or damages to the cartridge or threads, visible particulate buildup, or differences in breathing resistance. If any of this is noticed, dispose of the cartridge and open a new set.

Respirator Types

Dust Masks

Also known as a filtering facepiece respirator, a dust mask is a type of personal protective equipment (PPE) designed to filter out airborne particles, preventing them from entering the user’s respiratory system. It is recommended to use dust masks that are at least N95 rated for maximum effectiveness. 

N95

The most common particulate filtering facepiece respirators (FFRs) are N95 models. These disposable respirators filter at least 95% of airborne particles. They are not rated for oil-based particles.

There are many models and manufacturers for N95 respirators. OSU EH&S will provide recommendations based on the supply of respirators used in our fit test program (usually manufactured by 3M), although we can fit test any N95 model as long as it is appropriate for the user’s needs.

Half-Face Respirators

Half-face respirators are a type of air-purifying respirator (APR) that cover the nose and mouth while leaving the rest of the face exposed, creating a vacuum when the user inhales. This pulls air through a cartridge or filter, keeping harmful particles in the atmosphere from entering the respirator. The cartridge/filter type determines what the respirator will effectively protect against. EH&S can fit test most respirators manufactured by Honeywell North, Scott, or 3M - first time half-face respirator users who have not yet purchased a respirator will be fit with a Honeywell North 7700 Series Half-Face Respirator by default.

Full-Face Respirators

Full-face respirators are a type of air-purifying respirator (APR) that cover the nose, mouth, and eyes with a tightly sealed protective face shield. Like half-face respirators, they use attachable cartridges or filters to filter out contaminants in the atmosphere; additionally, these offer additional full-face protection and are therefore favorable for more hazardous contaminants. The cartridge/filter type determines what the respirator will effectively protect against. EH&S can fit test respirators manufactured by Honeywell North, Scott, or 3M - first time half-face respirator users who have not yet purchased a respirator will be fit with a Honeywell North 7700 Series Half-Face Respirator.

Powered Air Purifying Respirators

Powered Air Purifying Respirators (PAPRs) are a battery-operated device that uses a blower (often attached at the hip using a belt, although some are in the helmet) to force filtered or purified air through a tube into the hood / helmet, instead of relying on the negative pressure of inhalation. PAPR systems that use a loose-fitting hood do not require a fit test. Instead, they require annual training with EH&S on the pre-use checks and maintenance of the system. PAPR systems with a tightly sealed helmet still require annual fit testing.

Self-Contained Breathing Apparatus

Self-Contained Breathing Apparatuses (SCBAs) provides the user with a portable supply of purified air, often contained within a tank that is attached to the respirator through a tube. These are used in environments with hazardous or oxygen-deficient atmospheres, as APRs cannot be used in environments where oxygen levels are below 19.5%. Fit testing is required, as SCBAs use tightly sealed full-face respirators with specific attachments.

Cartridge Types

P100

The most common cartridges are P100 particulate filers. These screen particles at a 99.97% filter efficiency, making them the most effective filter for airborne particulates. P100 cartridges are commonly used to protect against dust, debris, mold, welding fumes, etc.

Organic Vapor

Organic vapor cartridges protect against a range of potentially harmful organic vapors, including acetone, toluene, gasoline, and oil-based solvents. As unfiltered air is pulled through the cartridge, activate carbon absorbs the organic vapors on a molecular level, allowing filtered air to pass through.

The migration of organic vapors can occur even when the cartridge is not being used, so it is important to change cartridges when there is noticeable tastes/smells/irritation while using the cartridge or according to manufacturer recommendations.

These cartridges are not to be used when the only air contaminant is a particulate, working in confined spaces, IDLH, or oxygen deficient atmospheres, there are chemicals for which cartridges cannot be used safely (e.g., isocyanates, hydrogen sulfide, etc.), or there is not a NIOSH-approved cartridge for the air contaminant or for the contaminant at the present concentrations.

Acid Gas

Acid gas cartridges work similarly to organic vapor cartridges and cover a separate range of potentially harmful gases, including chlorine, hydrogen chloride, sulfur dioxide, hydrogen fluoride, and chlorine dioxide. Most (including Honeywell North Acid Gas cartridges) also protect against formaldehyde. These are often used in manufacturing, pharmaceuticals, and civil engineering / wood sciences.

These cartridges are not to be used when the only air contaminant is a particulate, working in confined spaces, IDLH, or oxygen deficient atmospheres, there are chemicals for which cartridges cannot be used safely (e.g., isocyanates, hydrogen sulfide, etc.), or there is not a NIOSH-approved cartridge for the air contaminant or for the contaminant at the present concentrations.

Multi-Gas

Most manufacturers produce a cartridge that protects against a wide range of possible contaminants. This includes organic vapor, ammonia, methylamine, formaldehyde and acid gas (chlorine, hydrogen chloride, sulfur dioxide, hydrogen sulfide, hydrogen fluoride, chlorine dioxide). These are mostly used when research involves a wide array of chemicals or chemicals with unknown concentrations.

These cartridges are not to be used when the only air contaminant is a particulate, working in confined spaces, IDLH, or oxygen deficient atmospheres, there are chemicals for which cartridges cannot be used safely (e.g., isocyanates, hydrogen sulfide, etc.), or there is not a NIOSH-approved cartridge for the air contaminant or for the contaminant at the present concentrations.

Combination P100 / Vapor

The cartridge types listed above often come in “combination form”. This allows for protection against different types of gases, mists, and vapors, as well as protection against harmful airborne particulates.

Recordkeeping

EH&S Records

EH&S keeps records of annual fit testing and trainings using SciShield – these can be accessed by supervisors and employees/students. Additionally, EH&S documents JHA forms, Voluntary Use forms, and medical clearances using an internal shared database.

Unit Records

Individual units that use respirators should keep records of the signed JHA forms, voluntary respirator use forms, and cartridge use log. These should be stored with all other safety/training documentation for the unit. These records should be updated at least annually, or when a new employee joins the group.

Program Evaluation

The effectiveness of the respirator program should be evaluated at least annually by EH&S staff. Supervisors of respirator users should complete frequent unscheduled observations of employee activities throughout the work area to confirm proper respirator use by employees. Delinquencies in these observations should be handled through reminders and, if necessary, repeating the respiratory protection training module within SciShield. New respirator users will also be given thorough instruction during the fit test.