The respirator program outlined below is based on the requirements established in Section 1910.134(b) of the Occupational Safety and Health Standards (found in Title 29 of the Code of Federal Regulations) for an 11-point minimal acceptable respirator program:

1. Establish Written Operating Procedures
   You must develop a formal written document outlining every aspect of your respirator program. Some of the details which must be included are:
   • How contaminants are controlled.
   • How contaminant concentrations are measured.
   • How respirators are selected, used, cleaned, inspected, repaired and stored.
2. Respirator Selection
   Proper selection of respirators shall be made according to the guidance of ANSI Z88.2-1992. In choosing respirators, consider the nature and extent of the hazard, the work requirements and conditions, and the characteristics and limitations of the respirators available. When you examine the hazardous environment, some of the questions you should ask are:
   • What are the contaminants?
   • What are their concentrations?
   • Are they gaseous or particulate?
   • Do they have adequate warning properties?
   • Are they immediately dangerous to life or health?
   • Does the air contain at least 19.5% oxygen?
   • Are protective clothing and hand protection necessary?
3. Train Respirator Users
   Every respirator wearer must receive fitting instructions, including demonstrations and practice in how to determine if it fits properly.

   Keep in mind that respirators cannot be used if anything interferes with the seal of the facepiece to an individual's face. That includes sideburns, beards, temple pieces of eye glasses, severe scars and wrinkles, and even missing dentures.

4. Assign Individual Respirators Where Practicable
   When respirators are assigned individually, there is less chance that a worker will use one that doesn't give him or her the best protection. And sometimes it overcomes the unwillingness of an employee to wear a respirator if he or she thinks someone else has used it, and that it wasn't properly sanitized afterward.
5. Regularly Clean and Sanitize Respirators
   There is a three-step method of washing the respirator in a detergent or cleaner-sanitizer, rinsing it in warm water, and air drying it that is outlined in ANSI Z88.2-1992.
6. Respirator Storage
   Storing respirators in clean bags or other suitable containers in a clean and sanitary location maintains the integrity of your cleaning and maintenance program.
7. Respirator Inspection and Maintenance
   Inspection and maintenance of respirators in accordance with the manufacturer's instructions will ensure that the respirators, when properly used, will give the wearer the best possible protection.
8. Monitor the Work Area
   Make sure the right respirator is being used.
9. Continually Enforce and Evaluate the Respirator Program
   Frequent, random inspections shall be conducted by a qualified individual to assure that respirators are properly selected, used, cleaned, and maintained.
10. Medical Evaluation of Respirator Wearers
    If a potential respirator wearer is not physically able to perform the work using a respirator, the use of a respirator may create more problems than it solves.
11. Use Approved or Accepted Respirators
    The respirators you use in your work environment must be NIOSH/MSHA certified, where applicable, or be otherwise accepted to provide adequate protection for the hazards encountered.

    DUSTS are created when solid material breaks down and gives off fine particles that float in the air before settling by gravity. Dusts are produced by operations such as grinding, crushing, drilling, blasting, sanding, and milling.

    MISTS are particles formed from liquid materials by atomization and condensation processes. For example, mists can be created by spraying operations, plating operations, and mixing and cleaning operations.

    FUMES are created when solid materials vaporize under high heat. The metal vapor cools and condenses into an extremely small particle, with a particle size generally less than one micrometer in diameter. Fumes can come from operations such as welding, smelting, and pouring of molten metal.

    VAPORS are the gaseous state of substances that are either liquids or solids at room temperature. They are formed when solids or liquids evaporate. Gasoline is an example of a liquid that evaporates easily, producing gasoline vapors. Other examples are paint thinners and degreaser solvents.

Personal Protective Equipment Levels

Level A
Protection should be used when:

1. The hazardous substance has been identified and requires the highest level of protection for skin, eyes, and the respiratory system based on either the measured (or potential for) high concentration of atmospheric vapors, gases, or particulates; or the site operations and work functions involve a high potential for splash, immersion, or exposure to unexpected gases, vapors, or particulates of materials that are harmful to the skin or capable of being absorbed through the skin;
2. Substances with a high degree of hazard to the skin are known or suspected to be present, and skin contact is possible; or
3. Operations are being conducted in confined, poorly ventilated areas, and the absence of conditions requiring Level A have not yet been determined.

I. Level A - to be selected when the greatest level of respiratory protection is required: Positive pressure, full facepiece self-contained breathing apparatus (SCBA), or positive pressure supplied air respirator with escape SCBA, approved by the National Institute for Occupational Safety and Health (NIOSH).

Note: In 29CFR 1910.120 (g) (3) (iii), OSHA requires that Level A respiratory protection be used "when chemical exposure levels present will create a substantial possibility of immediate death, immediate serious illness or injury, or impair the ability to escape."

Level B
Level B protection should be used when:

1. The type and atmospheric concentration of substances have been identified and require a high level of respirator protection, but less skin protection;
2. 2. The atmosphere contains less than 19.5 percent oxygen; or
3. The presence of incompletely identified vapors or gases is indicated by a direct-reading organic vapor detection instrument, but vapors and gases are not suspected of containing high levels of chemicals harmful to skin or capable of being absorbed through the skin.

II. Level B - to be selected when the highest level of respiratory protection is necessary, but a lesser level of skin protection is needed: Positive pressure, full facepiece self-contained breathing apparatus (SCBA), or positive pressure air respirator with escape SCBA (NIOSH-approved).

Note: Level B respiratory protection specified by OSHA is identical to Level A respiratory protection. The hazards involve "atmospheres that present severe inhalation hazards and that do not represent a severe skin hazard; or that do not meet the criteria for use of air-purifying respirators."

Level C
Level C protection should be used when:

1. The atmospheric contaminants, liquid splashes, or other direct contact will not adversely affect or be absorbed through any exposed skin;
2. The types of air contaminants have been identified, concentrations measured, and an air-purifying respirator is available that can remove the contaminants; and
3. All criteria for the use of air-purifying respirators are met.

III. Level C - to be selected when the concentration(s) and type(s) of airborne substance(s) is known and the criteria for using air-purifying respirators are met:

1. Full-face or half-mask air-purifying respirators (NIOSH-approved);
2. Escape mask (optional);

Note: In 29CFR 1910.120 (g) (3) (iii) (vi) OSHA requires that respirators be selected and used in accordance with 29CFR 1910.134. Respirators (NIOSH-approved) other than those described in Levels A, B, C and D may be more appropriate and may be used to provide the proper level of protection. Thus, where Level A or B respiratory protection is not required (e.g., in a non-IDLH atmosphere), but air-purifying respirators are inadequate because of the presence of excessive concentration levels of gases or vapors having poor warning properties, suitable airline respirators may be used.

Level D
Level D protection should be used when:

1. The atmosphere contains no known hazard;
2. Work functions preclude splashes, immersion, or the potential for unexpected inhalation of or contact with hazardous levels of any chemicals.

IV. Level D - no respirator is required. However, OSHA does specify an "escape mask" as optional equipment to insure a safe escape should an inhalation hazard unexpectedly and suddenly appear.

New Respiratory Standard - 42CFR84

NIOSH (National Institute for Occupational Safety and Health) establishes new testing and certification requirements for particulate respirators and filters.

Reasons For Change

• Current certification technology is over 20 years old.
• Many advances in filter technologies, testing and measurement methods.
• Introduction of new workplace hazards, such as TB.
• Tests chosen so that filters can be used for any particulate size.

New Filter classifications

• No more dust/mist/fume/paint spray or pesticide classes.
• 3 new filter classifications _ N, R, P series.
• 3 levels of filtering efficiency _ 95%, 99%, 99.97%.
• New NIOSH approval numbers (TC 84A-XXX).

Three-year transition period

• Manufacturers can no longer sell existing particulate respirators after July 10, 1998.
• Customers may use current products (approved under NIOSH 30 CFR 11 tests) at least until July 10, 1998.
• Make changes to new products when it makes the most sense.