Preface
The basic purpose of a respirator is to protect the user from inhalation of hazardous atmospheres. When it is determined that a hazardous atmosphere exists, the first line of defense is to eliminate the hazard using engineering controls (i.e. ventilation). However, if engineering controls are infeasible due to time or financial constraints, then respirators must be used to protect workers. Additionally, respirators must be used when airborne contaminant sources cannot be controlled to a level below their occupational exposure limits (i.e. certain maintenance and repair operations, emergencies, or periods when ventilation system controls are being installed).
There are many variables that affect the degree of protection provided by respirators and the misuse of respirators can be hazardous to employee safety and health. Selection of the wrong equipment can result in the employee being exposed to increased concentrations of the harmful contaminant. Respirators that are not maintained and inspected can be less effective at reducing exposure to harmful contaminants, and can place a greater physical burden on the respiratory system. Respirators that are not clean can cause skin irritation or dermatitis. This program establishes standard operating procedures to ensure that respirators are selected, used, and maintained properly, and the potential hazards associated with misuse are eliminated.
Purpose
The potential for employee exposure to respiratory hazards exists during the performance of specific job duties. The purpose of this program is to ensure that employees receive education and training required to protect them from exposure to respiratory hazards. Controls such as ventilation and substitution of less toxic materials are the first line of defense. However, these controls are not always feasible for some operations, or they will not always completely control the identified hazards. In these situations, respirators and other protective equipment must be used.
Mandatory Use Of Respirators
This program applies to all employees who are required to wear respirators during normal work operations and during certain non-routine or emergency operations. The requirement to wear a respirator is determined based on the employee's potential exposure to respiratory hazards. Employees participating in the respiratory protection program do so at no cost to them.
Appendix C: Respirator Fit Test Form
Voluntary Use Of Respirators
Employees who voluntarily choose to use a respirator when it is not required are subject to the cleaning, maintenance and storage elements of this program. These requirements can be met by following the respirator manufacturer's instructions for the selected respirator(s).
Employees who voluntarily use filtering facepiece respirators (i.e., dust masks) are excluded from all requirements of this program.
Responsibilities: Respirator Program Administrator
The Corporate Safety Manager is responsible for overseeing the respiratory protection program and ensuring that all requirements are fully implemented.
Other Responsible Individuals
The Corporate Safety Manager has the authority to assign responsibility and accountability to employees or supervisors for each phase of this program.
Respiratory Hazard Evaluation
Due to the nature of Bodine's work, employees may encounter respiratory hazards at any place and at any time. Weather a respirator will or will not be required for a job may not be determined until the hazards of the job have been evaluated, especially if it is the first time at the particular site. The Lead Person or Supervisor must report changes in work processes that may result in increased employee exposure. Such conditions may include the use of new chemicals; a change in the way chemicals are processed, handled, or manipulated; or a change in environmental controls such as local or general ventilation systems.
Employees who believe that respiratory protection is needed during a particular activity should contact their supervisor. This information will be conveyed to the Corporate Safety Manager or assigned designee, who will ensure that the potential hazard is assessed, and the results of the assessment are communicated to the affected employees. If it is determined that respiratory protection is necessary, the Hazard Assessment Form will be updated accordingly.
Basis For Respirator Selection
Respirators have been selected on the basis of the hazards to which the employees are exposed. Guidance for respirator selection was obtained by reviewing the OSHA Technical Manual, Section VIII, Chapter 2.V. “Respirator Selection”. All respirators must be certified by the National Institute for Occupational Safety and Health (NIOSH) and shall be used in accordance with the terms of that certification. All filters, cartridges, and canisters must be labeled with the appropriate NIOSH certification number. The label must not be removed.
Workplace & User Factors
Potential workplace and user factors that could influence the selection of respirator types must also be considered. Workplace and user factors include, but are not limited to, the equipment or tools that will be used; excessive temperature or relative humidity; or any motion or travel required which can interfere with the type of respirator to be selected.
Face-piece Seal Protection
The use of respirators under conditions that would compromise the face-piece-to-face seal will not be permitted. Examples of these conditions include facial hair that interferes with the face-piece seal or valve function, absence of normally worn dentures, facial deformities (e.g., scars, deep skin creases, prominent cheekbones), or the use of jewelry or headgear that projects under the face-piece seal. Fit testing cannot be conducted if any of these conditions exists. Additionally, corrective glasses or goggles, or other personal protective equipment, must be worn in such a way that they do not interfere with the seal of the face-piece to the face.
Workplace Observations
The guidance and oversight of the proper use of respirators is the responsibility of the Supervisor or Lead Person, who will ensure that employees wear respirators when required, and that respirators are used correctly. The Corporate Safety Manager or assigned designee may at any time observe the workplace unannounced to ensure compliance.
Change Schedule For Cartridges
Bodine will make every attempt to use respirator cartridge brands equipped with end-of-service- life-indicators (ESLI) to determine when a cartridge should be changed. The cartridge will be changed when the ESLI indicates it is necessary or after eight hours of service, whichever comes first.
Due to the nature of Bodine's work, prior knowledge of what respiratory hazards are present may not exist until the site is evaluated. If no ESLI is available on the cartridge, the cartridge-changing schedule will be determined by using programs such as the online worksheet supplied by 3M Service Life Home Page, or by using “Breakthrough Beta Version 3.0.1" available for download. The “ezGuide v.2.2” will also estimate breakthrough times for North cartridges.
Filters
For respirators worn exclusively for protection against particles, filters, such as HEPA, will be changed according to the manufacturer's specification and whenever the wearer detects an increase in breathing resistance.
Fit Testing
Fit testing will be required for all employees who are required to wear respirators with a tight-fitting face-piece. Fit testing will be performed:
- After an employee has completed their medical evaluation and prior to being allowed to wear any respirator with a tight fitting face-piece in the work environment.
- Whenever a different respirator face-piece is used.
- At least annually thereafter.
- When there are changes in the employee's physical condition that could affect respiratory fit (e.g., obvious change in body weight, facial scarring, etc.)
Employees will be provided with several models and sizes of respirators so that they may find the optimal fit. Employees who voluntarily choose to use respirators in the absence of any atmospheric hazards are not required to be fit tested.
Appendix C: Respirator Fit Test Form
Initial Medical Evaluation
Employees who use respirators must be able to tolerate the physical and psychological stress imposed by respirator use. Employees will not be allowed to wear respirators until a physician or other licensed health care professional (PLHCP) has determined that they are medically able to do so. Any employee refusing the medical evaluation cannot work in an area requiring respirator use.
A powered air-purifying respirator (PAPR) will be provided to any employee if information from the PLHCP indicates that the employee can use a PAPR but not a negative pressure respirator. If, subsequent to this evaluation, the PLHCP determines that the employee is able to wear a negative pressure respirator, the supervisor will no longer be required to provide a PAPR to that employee.
Additional Medial Evaluations
Additional medical evaluation or medical reevaluation for any employee shall be required when:
- The employee reports medical signs or symptoms that are related to the employee's ability to use a respirator.
- The PLHCP, supervisor, or the Safety Representative observes that the employee is having a medical problem during fit testing or workplace respirator use.
- Information from the respiratory protection program, including observations made during fit testing and program evaluation, indicates a need for employee re-evaluation.
- A change occurs in workplace conditions (e.g., physical work effort, type of respirator used, protective clothing, temperature) that may result in a substantial increase in the physiological burden placed on an employee.
- The content of such additional medical evaluations will be determined by the PLHCP.
A supplemental medical questionnaire will be administered at least annually.
Cleaning & Disinfection
Respirators will be cleaned and disinfected in accordance with Appendix B-2 of 1910.134.
The Frequency Of Cleaning & Disinfecting
- Respirators that are issued for the exclusive use of an employee will be cleaned and disinfected as often as necessary to be maintained in a sanitary condition. Employees will be responsible to clean and disinfect respirators issued for their exclusive use.
- Respirators used by more than one employee will be cleaned and disinfected prior to being used.
- Respirators maintained for emergency use will be cleaned and disinfected after each use.
- Refer to Appendix B of this section for procedures.
Storage
Respirators will be stored so that they are protected against damage, contamination, dust, sunlight, temperature extremes, excessive moisture, and damaging chemicals. The Safety Representative is responsible to ensure that respirators intended for emergency use will be kept accessible to the work area. Emergency use respirators will not be kept in any area that might itself be involved in the emergency because such an area may become contaminated or inaccessible. Emergency use respirators will be stored in compartments or covers that are clearly marked to indicate that they contain emergency respirators and stored according to any applicable manufacturer instructions.
Emergency respirators will be readily available for use and will be stored in compartments labeled “FOR EMERGENCY USE ONLY.
Inspection
- Respirators used in routine situations will be inspected before each use and during cleaning.
- Respirator inspections will be conducted in accordance to the manufacturer's recommendations.
- Respirators designated for use in an emergency situation will be inspected at least monthly and in accordance with the manufacturer's instructions and checked for proper function before and after each use.
- Emergency escape-only respirators must be inspected before being carried into the workplace.
- Self-contained breathing apparatus (SCBA) will be inspected monthly and after each use.
- Respirators that are maintained for use in emergencies will be certified by documenting the date that the inspection was performed, the name or signature of the inspector, the findings of the inspection, any required remedial action, and a serial number or other means of identifying the inspected respirator. This information will be provided on the tag/label that is attached to the storage com compartment for the respirator.
- Inspection information for emergency respirators will be maintained until it is replaced following subsequent certification.
Repair
Supervisors and employees wearing respirators will ensure that respirators, which fail to pass inspection or are otherwise found to be defective, will be removed from service and repaired or adjusted properly. If a respirator cannot be repaired or adjusted, it will be discarded.
Only NIOSH-approved manufacturer's replacement parts designed for that respirator will be used. Repairs will be made in accordance with the manufacturer's recommendations and specifications regarding the type and extent of repairs to be performed.
Breathing Air Quality
Breathing air for atmosphere-supplying respirators will be of high purity, meets quality levels for content, and does not exceed certain contaminant levels and moisture requirements.
Cylinders
For supplied-air respirators (SARs), only Grade D breathing air shall be used in cylinders. The Safety Representative or designee will coordinate deliveries of compressed air with the vendor and require certification that the air in the cylinders meets the specifications of Grade D breathing air. Moisture content in the cylinders will not exceed a dew point of -50° F (-45.6° C) at 1 atmosphere pressure.
Training & Information
The Company will provide general orientation training to respirator users before the fit testing session. The content of the general training program is outlined in Appendix A of this section. In addition to the general training session, site specific training will be conducted as needed. This training focuses on the specific practices and policies of the work areas where respiratory protection is required, including the contents of the written respiratory protection program and the employees' responsibilities under it.
Employees who voluntarily use filtering facepiece (dust mask) respirators are exempt from the training requirements. Employees who voluntarily use elastomeric air-purifying respirators will receive limited training regarding cleaning and storage.
Program Evaluation
The Corporate Safety Manager or assigned designee is responsible to conduct evaluations of the workplace, as necessary. Periodic program evaluation is required to ensure that the provisions of the respiratory protection program are being implemented for all employees using respirators. In addition, evaluations will be conducted to ensure the continued effectiveness of the program. Evaluations of the workplace will determine whether the correct respirators are being used and worn properly and will also serve to determine whether the training program is effective.
The Corporate Safety Manager or assigned designee is responsible to periodically monitor employee use of respirators to ensure that they are being used and worn properly.
In addition, the Corporate Safety Manager or assigned designee will regularly consult with employees wearing respirators to acquire the employees' views on program effectiveness and to identify any problems so that corrective action can be taken.
The following factors will be evaluated to determine program effectiveness:
- Respirators are properly fitted and if employees are able to wear respirators without interfering with effective workplace performance.
- Respirators are correctly selected for the hazards encountered.
- Respirators are used properly depending on the workplace conditions encountered.
- Respirators are being maintained and stored properly.
The Corporate Safety Manager will be responsible to correct any problems associated with wearing a respirator that are identified by employees or that are revealed during any other part of this evaluation.
Medical Records
The Corporate Safety Manager or Safety Representative will retain a copy of the PLHCP's written recommendation for each employee subject to medical evaluation. Each employee's completed medical questionnaire, results of relevant medical tests, examinations, and diagnosis, etc., will be maintained by the PHLCP for a period of 30 years. Records of medical evaluations will be made available as specified in 29 CFR 1910.1020.
Fit Test Results
The Program Administrator will retain fit test records for respirator users until the next fit test is administered. These records consist of:
- Name or identification of the employee tested
- Make, model, and size of the respirator fitted;
- Date of the fit test;
Additionally, each employee will retain fit testing results on a laminated card.
Appendix C: Respirator Fit Test Form
Training Records
The Program Administrator will retain employee training records that include the names of trained employees and the dates when training was conducted.
All written materials required to be maintained under the record keeping requirements will be made available or review, upon request to the employee who is subject to the records. Fit testing and training will be documented using the forms in Appendix C.
Voluntary Respirator Users
Respirator use is encouraged, even when exposures are below the exposure limit, to provide an additional level of comfort and protection for workers. However, if a respirator is used improperly or not kept clean, the respirator itself can become a hazard to the worker. Sometimes, workers may wear respirators to avoid exposures to hazards, even if the amount of hazardous substance does not exceed the limits set by OSHA standards. The worker needs to take certain precautions if you voluntarily wear a respirator to be sure that the respirator itself does not present a hazard.
The worker should do the following:
- Read and follow all instructions provided by the manufacturer on use, maintenance, cleaning and care, and warnings regarding the respirators limitations.
- Choose respirators and cartridges that are certified for use to protect against the contaminant of concern. NIOSH, the National Institute for Occupational Safety and Health of the U.S. Department of Health and Human Services, certifies respirators. A label or statement of certification should appear on the respirator or respirator packaging. It will indicate what the respirator is designed for and level of protection.
- Do not wear a respirator into atmospheres containing contaminants for which a respirator is not designed to protect against. For example, a respirator designed to filter dust particles will not protect against gases, vapors, or very small solid particles of fumes or smoke.
- Keep track of the respirators so that workers do not mistakenly use someone else's respirator.
Appendix A
Fit Testing Procedures General Requirements
The employer shall conduct fit testing using the following procedures. The requirements in this appendix apply to all OSHA-accepted fit test methods, both QLFT and QNFT.
The test subject shall be allowed to pick the most acceptable respirator from a sufficient number of respirator models and sizes so that the respirator is acceptable to, and correctly fits, the user.
Prior to the selection process, the test subject shall be shown how to put on a respirator, how it should be positioned on the face, how to set strap tension and how to determine an acceptable fit. A mirror shall be available to assist the subject in evaluating the fit and positioning of the respirator. This instruction may not constitute the subject's formal training on respirator use, because it is only a review.
The test subject shall be informed that he/she is being asked to select the respirator that provides the most acceptable fit. Each respirator represents a different size and shape, and if fitted and used properly, will provide adequate protection.
The test subject shall be instructed to hold each chosen face piece up to the face and eliminate those that obviously do not give an acceptable fit.
The more acceptable face pieces are noted in case the one selected proves unacceptable; the most comfortable mask is donned and worn at least five minutes to assess comfort. Assistance in assessing comfort can be given by discussing the points in the following item A.6. If the test subject is not familiar with using a particular respirator, the test subject shall be directed to don the mask several times and to adjust the straps each time to become adept at setting proper tension on the straps.
Assessment of comfort shall include a review of the following points with the test subject and allowing the test subject adequate time to determine the comfort of the respirator:
- Position of the mask on the nose
- Room for eye protection
- Room to talk
- Position of mask on face and cheeks
The following criteria shall be used to help determine the adequacy of the respirator fit:
- Chin properly placed
- Adequate strap tension, not overly tightened
- Fit across nose bridge
- Respirator of proper size to span distance from nose to chin
- Tendency of respirator to slip
- Self-observation in mirror to evaluate fit and respirator position.
The test subject shall conduct a user seal check, either the negative and positive pressure seal checks described in Appendix B-1 of this section or those recommended by the respirator manufacturer which provide equivalent protection to the procedures in Appendix B-1. Before conducting the negative and positive pressure checks, the subject shall be told to seat the mask on the face by moving the head from side-to-side and up and down slowly while taking in a few slow deep breaths. Another face piece shall be selected and retested if the test subject fails the user seal check tests.
The test shall not be conducted if there is any hair growth between the skin and the face piece sealing surface, such as stubble beard growth, beard, mustache or sideburns which cross the respirator sealing surface. Any type of apparel, which interferes with a satisfactory fit, shall be altered or removed.
If a test subject exhibits difficulty in breathing during the tests, she or he shall be referred to a physician or other licensed health care professional, as appropriate, to determine whether the test subject can wear a respirator while performing her or his duties.
If the employee finds the fit of the respirator unacceptable, the test subject shall be given the opportunity to select a different respirator and to be retested.
Exercise regimen. Prior to the commencement of the fit test, the test subject shall be given a description of the fit test and the test subject's responsibilities during the test procedure. The description of the process shall include a description of the test exercises that the subject will be performing. The respirator to be tested shall be worn for at least 5 minutes before the start of the fit test.
The fit test shall be performed while the test subject is wearing any applicable safety equipment that may be worn during actual respirator use which could interfere with respirator fit.
Test Exercises
Employers must perform the following test exercises for all fit testing methods prescribed in this appendix, except for the CNP quantitative fit testing protocol and the CNP REDON quantitative fit testing protocol. For these two protocols, employers must ensure that the test subjects (i.e., employees) perform the exercise procedure specified in Part I.C.4(b) of this appendix for the CNP quantitative fit testing protocol, or the exercise procedure described in Part I.C.5(b) of this appendix for the CNP REDON quantitative fit testing protocol. For the remaining fit testing methods, employers must ensure that employees perform the test exercises in the appropriate test environment in the following manner:
- Normal breathing. In a normal standing position, without talking, the subject shall breathe normally.
- Deep breathing. In a normal standing position, the subject shall breathe slowly and deeply, taking caution so as not to hyperventilate.
- Turning head side to side. Standing in place, the subject shall slowly turn his/her head from side to side between the extreme positions on each side. The head shall be held at each extreme momentarily so the subject can inhale at each side.
- Moving head up and down. Standing in place, the subject shall slowly move his/her head up and down. The subject shall be instructed to inhale in the up position (i.e., when looking toward the ceiling).
- Talking. The subject shall talk out loud slowly and loud enough so as to be heard clearly by the test conductor. The subject can read from a prepared text such as the Rainbow Passage, count backward from 100, or recite a memorized poem or song.
Rainbow Passage
”When the sunlight strikes raindrops in the air, they act like a prism and form a rainbow. The rainbow is a division of white light into many beautiful colors. These take the shape of a long round arch, with its path high above, and its two ends apparently beyond the horizon. There is, according to legend, a boiling pot of gold at one end. People look, but no one ever finds it. When a man looks for something beyond reach, his friends say he is looking for the pot of gold at the end of the rainbow.”
Grimace
The test subject shall grimace by smiling or frowning. (This applies only to QNFT testing; it is not performed for QLFT)
Bending over
The test subject shall bend at the waist as if he/she were to touch his/her toes. Jogging in place shall be substituted for this exercise in those test environments such as shroud type QNFT or QLFT units that do not permit bending over at the waist.
Normal breathing
Same as exercise (1).
Each test exercise shall be performed for one minute except for the grimace exercise which shall be performed for 15 seconds. The test subject shall be questioned by the test conductor regarding the comfort of the respirator upon completion of the protocol. If it has become unacceptable, another model of respirator shall be tried. The respirator shall not be adjusted once the fit test exercises begin. Any adjustment voids the test, and the fit test must be repeated.
Irritant Smoke (Stannic Chloride) Protocol
This qualitative fit test uses a person's response to the irritating chemicals released in the "smoke" produced by a stannic chloride ventilation smoke tube to detect leakage into the respirator.
General Requirements & Precautions
The respirator to be tested shall be equipped with high efficiency particulate air (HEPA) or P100 series filter(s).
Only stannic chloride smoke tubes shall be used for this protocol.
No form of test enclosure or hood for the test subject shall be used.
The smoke can be irritating to the eyes, lungs, and nasal passages. The test conductor shall take precautions to minimize the test subject's exposure to irritant smoke. Sensitivity varies, and certain individuals may respond to a greater degree to irritant smoke. Care shall be taken when performing the sensitivity screening checks that determine whether the test subject can detect irritant smoke to use only the minimum amount of smoke necessary to elicit a response from the test subject.
The fit test shall be performed in an area with adequate ventilation to prevent exposure of the person conducting the fit test or the build-up of irritant smoke in the general atmosphere.
Sensitivity Screening Check
The person to be tested must demonstrate his or her ability to detect a weak concentration of the irritant smoke. The test operator shall break both ends of a ventilation smoke tube containing stannic chloride, and attach one end of the smoke tube to a low flow air pump set to deliver 200 milliliters per minute, or an aspirator squeeze bulb. The test operator shall cover the other end of the smoke tube with a short piece of tubing to prevent potential injury from the jagged end of the smoke tube.
The test operator shall advise the test subject that the smoke can be irritating to the eyes, lungs, and nasal passages and instruct the subject to keep his/her eyes closed while the test is performed.
The test subject shall be allowed to smell a weak concentration of the irritant smoke before the respirator is donned to become familiar with its irritating properties and to determine if he/she can detect the irritating properties of the smoke. The test operator shall carefully direct a small amount of the irritant smoke in the test subject's direction to determine that he/she can detect it.
Irritant Smoke Fit Test Procedure
The person being fit tested shall don the respirator without assistance, and perform the required user seal check(s).
The test subject shall be instructed to keep his/her eyes closed.
The test operator shall direct the stream of irritant smoke from the smoke tube toward the face seal area of the test subject, using the low flow pump or the squeeze bulb. The test operator shall begin at least 12 inches from the face piece and move the smoke stream around the whole perimeter of the mask. The operator shall gradually make two more passes around the perimeter of the mask, moving to within six inches of the respirator.
If the person being tested has not had an involuntary response and/or detected the irritant smoke, proceed with the test exercises.
The exercises identified in section I.A. 14. of this appendix shall be performed by the test subject while the respirator seal is being continually challenged by the smoke, directed around the perimeter of the respirator at a distance of six inches.
If the person being fit tested reports detecting the irritant smoke at any time, the test is failed. The person being retested must repeat the entire sensitivity check and fit test procedure.
Each test subject passing the irritant smoke test without evidence of a response (involuntary cough, irritation) shall be given a second sensitivity screening check, with the smoke from the same smoke tube used during the fit test, once the respirator has been removed, to determine whether he/she still reacts to the smoke. Failure to evoke a response shall void the fit test.
If a response is produced during this second sensitivity check, then the fit test is passed.
Appendix B - Procedures for Cleaning Respirators
Remove filters, cartridges, or canisters. Disassemble facepieces by removing speaking diaphragms, demand and pressure- demand valve assemblies, hoses, or any components recommended by the manufacturer. Discard or repair any defective parts.
Wash components in warm (43 deg. C [110 deg. F] maximum) water with a mild detergent or with a cleaner recommended by the manufacturer. A stiff bristle (not wire) brush may be used to facilitate the removal of dirt.
Rinse components thoroughly in clean, warm (43 deg. C [110 deg. F] maximum), preferably running water. Drain.
When the cleaner used does not contain a disinfecting agent, respirator components should be immersed for two minutes in one of the following:
- Hypochlorite solution (50 ppm of chlorine) made by adding approximately one milliliter of laundry bleach to one liter of water at 43 deg. C (110 deg. F); or,
- Aqueous solution of iodine (50 ppm iodine) made by adding approximately 0.8 milliliters of tincture of iodine (6-8 grams ammonium and/or potassium iodide/100 cc of 45% alcohol) to one liter of water at 43 deg. C (110 deg. F); or,
- Other commercially available cleansers of equivalent disinfectant quality when used as directed, if their use is recommended or approved by the respirator manufacturer.
Rinse components thoroughly in clean, warm (43 deg. C [110 deg. F] maximum), preferably running water. Drain. The importance of thorough rinsing cannot be overemphasized. Detergents or disinfectants that dry on face pieces may result in dermatitis. In addition, some disinfectants may cause deterioration of rubber or corrosion of metal parts if not completely removed.
Components should be hand-dried with a clean lint-free cloth or air-dried.
Re-assemble facepiece, replacing filters, cartridges, and canisters where necessary.
Test the respirator to ensure that all components work properly.
