OSHA's requirements for respiratory protection are outlined in the OSHA standard for respiratory protection, specifically under 29 CFR 1910.134. These requirements encompass various aspects of respiratory protection programs, including the types of respirators, selection criteria, and proper maintenance and use.

Respiratory Protection Program

Program Requirements

Under 29 CFR 1910.134(c), employers are required to establish and maintain a respiratory protection program to ensure the safety and health of their workers. This program must include specific procedures and elements that are clearly outlined and strictly followed, including:

• Written Procedures: Employers must develop and implement written procedures regarding the use of respirators in the workplace.
• Program Evaluation: The program must be regularly evaluated for its effectiveness, and modifications must be made to reflect changes in workplace conditions that affect respirator use.
• Administrator Role: A program administrator must be designated, who is qualified by appropriate training or experience that is commensurate with the complexity of the program to oversee the implementation and ongoing evaluation of the program.

Worker Training and Fit Testing

Comprehensive training must be provided to workers who are required to use respirators. The training should cover all aspects of respirator use, including:

• Proper Handling and Usage: Workers must understand how to put on, take off, adjust, and wear respirators.
• Fit Testing: Required for all tight-fitting facepiece respirators, fit testing ensures that the equipment properly fits the wearer. Fit testing must be performed before initial use, whenever a different respirator facepiece is used, and at least annually thereafter.
• Maintenance and Care: Detailed instructions must be provided on the regular maintenance and care of respirators, including cleaning, disinfecting, storing, and inspecting for wear and tear.

Medical Evaluations

Prior to fitting a worker with a respirator and as part of the ongoing use of respirators, medical evaluations are required to ensure that employees are medically able to wear their assigned respirators under working conditions. The evaluation should assess the health and physical conditions that might limit the use of a respirator, such as asthma or heart issues.

Respirator Selection

Hazard Evaluation

Under OSHA standard 29 CFR 1910.134(d), the selection of respirators is a critical component that hinges on a proper hazard evaluation. Employers are required to assess the respiratory hazards in the workplace, which involves identifying and quantifying the types of hazardous substances present, whether they are particulates, gases, or vapors. This evaluation must include an analysis of the exposure levels to ensure that the chosen respirator can reduce exposure to below the permissible exposure limits (PELs). The assessment should also consider the physical and chemical properties of the contaminants, as well as environmental factors such as temperature and humidity that could affect respirator performance.

For environments such as those found in the manufacturing of chemicals or the processing of minerals, where workers might be exposed to toxic dusts or fumes, a thorough hazard evaluation is especially vital. This dictates the type of respirator required and also impacts additional components of the respiratory protection program, including training and fit testing.

Respirator Types

The selection of the appropriate respirator type depends on the outcome of the hazard evaluation:

• Air-Purifying Respirators (APRs): These are designed for environments where the air pollutant levels are known and controlled to within safe limits defined by environmental health standards. APRs use filters, cartridges, or canisters to remove specific contaminants from the air by capturing pollutants through a physical barrier or by chemical absorption.
• Atmosphere-Supplying Respirators: These respirators provide the wearer with breathing air from a source independent of the ambient atmosphere. They are used in situations where air purification is inadequate because the environment is oxygen-deficient or the contaminant cannot be filtered effectively.
• Supplied-Air Respirators (SARs) or Self-Contained Breathing Apparatus (SCBA): SARs deliver air to the respirator wearer through a hose from a stationary source of compressed air. They are commonly used in applications such as spray painting or in environments with hazardous fumes. SCBAs, on the other hand, are worn for entry into confined spaces or in situations where toxic substances are highly concentrated, providing a higher level of protection as they are equipped with their own breathable air supply.

APF Standards

The Assigned Protection Factors (APFs) are essential for selecting the correct respirator and are defined in Table 1 of 29 CFR 1910.134. These factors indicate the level of respiratory protection that a respirator or class of respirators is expected to provide to employees and are used to select the appropriate respirator based on the hazard evaluation. For instance:

• Half-Mask Respirators: Generally have an APF of 10, meaning they can protect against contaminants up to 10 times the PEL.
• Full-Face Respirators: Offer an APF of 50, suitable for higher-risk environments where the contaminant concentration is up to 50 times the PEL.
• Supplied-Air Respirators (Hooded): Have an APF of 25 to 1000, depending on whether they operate in continuous-flow mode, pressure-demand, or other specifications.
• SCBAs: Depending on the mode (pressure-demand, open/closed circuit), these can have APFs from 10,000 to 10,000+, providing maximum protection for the most hazardous conditions.

Use and Maintenance

Correct Use

In line with OSHA standard 29 CFR 1910.134(c)(1)(vii), ensuring the correct use of respirators is imperative for their effectiveness. Each respirator must be properly fitted to the wearer, and users must perform seal checks every time the respirator is put on. This process, crucial for safety, involves both positive and negative pressure checks that confirm whether the mask forms a tight seal against the face, which is critical in preventing contaminants from bypassing the filter.

For tasks in environments such as construction sites where dust and particulates are prevalent, or in manufacturing settings where chemical vapors and gases are emitted, a properly sealed respirator is vital. It not only maximizes the wearer’s protection but also enhances the respirator’s efficiency in filtering harmful substances.

Maintenance and Care

According to 29 CFR 1910.134(c)(1)(viii), respirators must be maintained in a clean and sanitary condition. The maintenance process includes regularly cleaning and disinfecting them according to the manufacturer's instructions. This typically involves using warm water and mild cleaning solutions or disinfecting wipes designed for respirator masks. After cleaning, respirators should be thoroughly rinsed and allowed to dry completely before reuse.

Regular inspections are also a must, as per OSHA’s guidelines, to check for any signs of deterioration or damage such as cracks in the facepiece, elasticity loss in the straps, and compromised seals or valves. Any defective parts must be repaired or replaced immediately to maintain the respirator’s integrity and functionality. These practices are essential in environments involving heavy machinery and abrasive materials, where respirators are subjected to frequent wear and tear.

Training and Information

Training is a critical component of the respiratory protection program, as stated in 29 CFR 1910.134(k). Workers must be trained on the practical aspects of respirator use, which includes how to properly put on and remove the respirator, how to perform seal checks, and how to maintain the respirator in good working condition. This training must be comprehensive and understandable for all employees, conducted at the initial assignment and at least annually thereafter.

Furthermore, whenever there are changes in the workplace that affect the type of respirators used, or changes in the respirators themselves, retraining is required. This ensures that all users are up to date with the latest safety practices and are using their equipment correctly. In industries where workers face high levels of airborne hazards, such as in mineral processing or heavy construction, effective training is crucial in preventing occupational illnesses.

Program Evaluation

OSHA mandates regular evaluations of the respiratory protection program to assess its effectiveness (29 CFR 1910.134(l)). These evaluations should involve consultations with employees to identify potential issues within the program and to gather suggestions for improvement. Evaluations should check if all elements of the program, from the written procedures to the execution of training and maintenance, are being implemented correctly.

This ongoing assessment helps to ensure that the program is continually updated in response to any changes in workplace conditions, respirator technology, or governmental regulations. It is particularly important in dynamic fields such as industrial manufacturing and construction, where new respiratory hazards can emerge as new materials and processes are introduced.