RESPIRATORY PROTECTION PROGRAM

ENVIRONMENTAL HEALTH & SAFETY Fourth Revision August 2006 Copyright 1990 Iowa State University Research Foundation, Inc. Iowa State University Ames, Iowa

I. INTRODUCTION
The control of occupational disease caused by breathing contaminated air should be accomplished through engineering control measures. For example, general and local ventilation, isolation of a process, or substitution of a less hazardous material are all effective engineering controls that should be used to eliminate or reduce airborne hazards. Respirators should not be used if engineering controls are feasible. The issuance of respirators to employees plays a significant role in employee health and safety at Iowa State University (ISU). Because of the importance of proper respirator selection, fitting, and medical surveillance as well as the need to meet regulatory requirements, supplying a respirator to an ISU employee should be done as specified in this manual. Purpose The purpose of the ISU Respiratory Protection Program is to: Provide written procedures that can be used to administer an effective respiratory protection program which will prevent exposure to airborne contaminants and thus maintain employee health. Outline specific information to facilitate: o o o Appropriate respirator selection. Employee respirator training, fit-testing, care and use. Medical surveillance to evaluate an employee's health and ability to wear a respirator.

Meet the requirements of a written respiratory protection program as outlined in the revised 1998 Occupational Safety and Health Administration (OSHA) standard 29 CFR 1910.134. Scope The Respiratory Protection Program includes all respirators. Definitions of respirator types and related items are listed in Appendix C. Examples include: Dust mask respirators, such as the 3M 8210 dust mask. Half-face chemical cartridge respirators, such as the MSA Comfo II and 3M Easi-Air. Full-face chemical cartridge respirators, such as the 3M Easi-Air and MSA Ultra Twin. Powered-air purifying respirators (PAPR), such as the RACAL PAPR.
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 Air-line respirators, also known as supplied air respirators. Self-contained breathing apparatus (SCBA), such as the Scott Airpack. Statement of Responsibilities University Iowa State University is responsible for ensuring the safety of its employees and for complying with all applicable requirements of state and federal regulations. Because of the importance the administration places on safety, ISU employees at all levels to are encouraged to promote positive attitudes regarding safety, incorporate safety into their work practices, and cooperate fully in the implementation of safety-related programs. Departments Whenever employees are exposed to airborne contaminants, departments must ensure that employees complete a Hazard Inventory Form (see the Occupational Medicine Manual). Based on the information provided on the Hazard Inventory Form, EH&S will determine the need for employee inclusion in the ISU Respiratory Protection Program (air monitoring will be conducted as appropriate). Specifically, departmental supervisors are to ensure that: o Employees receive approval to wear respirators from the Occupational Medicine physician, receive training, fill out appropriate paperwork, and are fit-tested (are certified) before respirators are used. Approved respirators and cartridges are available as needed. Proper respirators and cartridges are used, based on the employee's job hazard assessment. Employee respirators are inspected and maintained on a regular basis. EH&S is contacted when questions or problems arise.

o o o o

Environmental Health and Safety To assist university departments, EH&S provides oversight and technical consultation on environmental, health and safety issues at ISU. EH&S has developed the ISU Respiratory Protection Program and will assist individual departments in the implementation of a respiratory protection program for their areas. Specifically, EH&S will: o o o o Designate a program administrator (occupational health manager). Develop and monitor the ISU Respiratory Protection Program. Assist supervisors with hazard assessments and respirator selection. Provide respirator certification, training, fit-testing and recordkeeping.

Employees Employees are responsible for: o o Observing all practices and procedures contained in the ISU Respiratory Protection Program. Ensuring correct respirator and cartridge combinations are used for specific jobs or tasks.
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o o o

Attending designated training sessions. Reporting hazardous or unsafe conditions to their supervisor(s). Observing all other general safety practices.

Occupational Medicine Occupational is responsible for: o o o o o Reviewing the ISU Medical Questionnaire for Respiratory Protective Equipment form. Performing necessary medical tests. Granting approval for respirator usage. Retaining necessary confidential medical records. Notifying EH&S of potential problems reported by the employees or the Occupational Medicine Physician.

Checklist for Obtaining a Respirator at ISU Summarized below are the general steps or procedures necessary to properly and legally obtain a respirator at ISU: The supervisor and/or employee will contact EH&S to assess the employees need for a respirator. Hazard Inventory and Medical Questionnaire for Respiratory Protective Equipment forms will be sent to the employee and supervisor for completion. The employee may also sign up for respirator training at this time. The supervisor and/or employee fills out the Hazard Inventory Form (see the Occupational Medicine Manual) and checks all pertinent hazards. At minimum, Respirator User (A022) should be checked on the form. All Hazard Inventory Forms must be signed by both the employee and the supervisor. The employee brings this form to EH&Ss Initial Respirator Training class. The employee completes the Medical Questionnaire (Appendix A) and sends it to Occupational Medicine (G11 TASF) for a medical review. The employee schedules an appointment at Occupational Medicine for an initial exam to determine fitness to wear a respirator. The Occupational Medicine physician reviews the questionnaire and completes an initial exam. Once approval is granted, the employee is given the Medical Approval for Respirator Use form (last page of the Medical Questionnaire). This form, signed by the Occupational Medicine physician, signifies that the employee can wear a respirator. Occupational Medicine will also send a copy of the Medical Approval for Respirator Use form to EH&S. Employee completes respirator training and fit-testing at EH&S. EH&S will issue a Respirator Prescription, listing respirator type, size and cartridige type. To purchase a respirator, the employee takes the Respirator Prescription, along with a purchase order, to ISU Central Stores.

Employees exposed to non-hazardous levels of airborne contaminants who wear only dust mask type respirators may be granted specific exemptions to ISU Respiratory Protection Program requirements. See Voluntary Dust Mask Use in Section III.

II. MEDICAL EVALUATION

A medical evaluation is required by OSHA's Respiratory Protection Standard (29 CFR 1910.134) for employees who wear respirators. OSHA requires that the medical evaluation consist of, at minimum, completion of the Medical Questionnaire for Respiratory Protective Equipment by the employee and review of the questionnaire by a licensed health care professional. This requirement is intended to assure that employees are physically able to wear a respirator. As a result, any ISU employee requiring a respirator must participate in ISUs Occupational Medicine Program and receive medical approval from the Occupational Medicine Physician prior to respirator use.* Participation in the Occupational Medicine Program requires completion of a Hazard Inventory Form (see the Occupational Medicine Manual) and a Medical Questionnaire for Respiratory Protective Equipment. The Hazard Inventory form is to be completed by all employees who are exposed to hazards in the workplace. A new form should be f illed out for both new employees and current employees who have had chang es in job hazards or conditions. Once completed, the forms should be forwarded to EH&S, 2809 Daley Drive. Once this has been completed, a medical evaluation can be scheduled. The Medical Questionnaire for Respiratory Protective Equipment must be completed and returned to Occupational Medicine for review. The employee should then schedule an appointment at Occupational Medicine for an initial exam to determine fitness to wear a respirator. Once approved, copies of the written Medical Approval for Respirator Use will be forwarded to the employee and to EH&S. Medical Review Frequency Following National Institute of Occupational Safety and Health (NIOSH) guidelines, medical evaluations for respirator users at ISU will be conducted using the following schedule: AGE Less than 35 years 35-44 years 45 years or older MEDICAL REVIEW FREQUENCY Every 5 years after baseline Every 2 years after baseline Every year after baseline

Annual medical reviews are required for all SCBA respirator users. More frequent medical reviews may be required in special cases as determined by the Occupational Medicine physician.
*

Specific information about the Occupational Medicine Program can be obtained by requesting a copy of the Occupational Medicine Manual from EH&S, 2809 Daley Drive.

III. RESPIRATOR APPROVAL, SELECTION, AND PURCHASE

Approval All respirators used at ISU must be approved by the National Institute for Occupational Safety and Health (NIOSH) and carry the NIOSH approval label. All respirators sold by ISU Central Stores carry the NIOSH approval label. Selection Proper respirator selection depends on the type of contaminant, expected airborne concentration, and other factors such as oxygen concentration. Potential inhalation hazards must be assessed before the correct respirator can be selected. EH&S will assist departments in th e evaluation and measurement of job hazards and ultimately recommend the type of respirator to be used. Departmental supervisors shall ensure that proper respirators and cartridges are used, based on the employees job hazard assessment. Purchase A written prescription from EH&S is required for respirator/cartridge purchases at Central Stores. Prescriptions may be obtained from EH&S after completion of training and fit testing. This will ensure that the proper respirator/cartridge is selected for the job and that the appropriate hazard assessment and training have been completed (see Appendix A - EH&S Respirator Prescription form). Respirators purchased through other sources must be approved in writing by EH&S before use. Voluntary Dust Mask Use Employees who voluntarily use dust mask respirators will not be required to have a medical review or respirator training at EH&S. However, all voluntary dust mask users must read a short training policy sheet titled, Instructions for Voluntary Dust Mask Respirator Use at ISU (see Appendix B). This policy is distributed at Central Stores when dust masks are purchased. The following conditions must exist in order for dust mask respirators to be used voluntarily: Exposure to airborne contaminants is below OSHA permissible exposure limits (PELs) Exposure is only to non-toxic nuisance materials (plant dust, agar dust, etc.) There is no exposure to airborne infectious disease agents The dust mask is not worn to reduce exposure to gases or vapors
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IV. RESPIRATOR TRAINING AND FIT-TESTING

All respirator users at ISU are required to have annual training and fit-testing. Initial and recertification classes ar e held each month at EH&S, 2809 Daley Drive . Employees can be enrolled in the classes by calling EH&S (294-2193). Training classes will provide employees with information about: Workplace respiratory hazards Proper respirator selection and use Proper respirator fit Respirator limitations and inspection techniques Chemical cartridge end of service life indicators Respirator donning Respirator seal checks Proper respirator maintenance (cleaning) Proper respirator storage

Training Notification Employees are notified of required respirator training and f it testing via a m emo sent to their supervisor. This correspondence: Identifies those employees who need certification (initial or recertification Includes a request for information on changes in employee status and/or changes in respiratory hazard exposures. Indicates times and places to schedule training with EH&S

If employees fail to meet respirator certification requirements, they will be dropped from the ISU Respiratory Protection Program. Letters will be sent to supervisors informing them of any employee dropped from the program. Train the Trainer EH&S has established a Train-the-Trainer Program for departments which have a large number of dust mask users. EH&S will train designated employees to perform necessary procedures for dust mask respirators. All other types of respirator training and fit testing shall be performed by EH&S. Respirator training program outlines and attendance sheets are kept on file by EH&S.

V. RESPIRATOR LIMITATIONS
Cloth/paper dust mask respirators used voluntarily are limited to use with nuisance dusts only. Air purifying respirators (defined in Appendix C) must NOT be used in: Atmospheres that are oxygen deficient (< 19.5% oxygen). Atmospheres that are immediately dangerous to life or health (IDLH). Atmospheres with contaminants that cannot be removed by the respirator cartridge. Atmospheres that contain a contaminant whose concentration exceeds the assigned protection factor (rating) of the respirator. Atmospheres that contain a contaminant which has poor warning properties.

Emergency situations often require the highest level of respiratory protection. Atmospheres which have not been characterized (monitored) should be treated as though they are immediately dangerous to life and health (IDLH). Supplied-air respirators such as the selfcontained breathing apparatus (SCBA) or air-line respirator may be used in these atmospheres. However, emergency situations and I DLH entry must be handled on a case-by-case basis by EH&S. This will ensure that appropriate hazard assessments and mandatory training and fittesting have been performed.

VI. RESPIRATOR CARTRIDGE CHANGEOUT SHEDULES

The service life of a cartridge is the length of time the absorbing material in a chemical cartridge is effective in keeping contaminants out of the respirator. To ensure that chemical cartridges are replaced before the service life ends, a cartridge change-out schedule must be developed and followed. EH&S staff are available to assist departments in complying with this regulatory requirement. Listed below are OSHA-recognized rules of thumb that can be used to estimate cartridge service life: If the chemicals boiling point is >70C (158F) and the concentration is less than 200 ppm you can expect a service life of 8 hours at a normal work rate. Service life is inversely proportional to work rate. Reducing concentration by a factor of 10 will increase the service life by a factor of 5. Humidity above 85% will reduce service life by 50%.

In the absence of a change-out schedule for specific operations, cartridges should be changed out at the end of each day or workshift.

VII. RESPIRATOR MAINTENANCE

Cleaning Employees are responsible for ensuring that their respirators are used and stored in a clean condition. Disposable dust masks can be reused, but should be discarded when dirty. Alcohol wipe pads may be used on half-face, full-face and air-supplied respirators needing light cleaning. Respirators that need thorough cleaning should be taken apart and washed in warm water with a mild commercial detergent. Detergents are available through ISU Central Stores. After cleaning, respirators should be dried, reassembled and stored in their box or a plastic bag. Once stored, respirators should not have objects resting against them. Any respirator that is shared must be cleaned and disinfected after each use. Replacement Parts All respirators should be inspected before each use and again when reassembled after cleaning. Any parts that are defective should be r eplaced with the manufacturers replacement parts. Parts can be obtained through ISU Central Stores. SCBA Air Quality and Inspection Compressors used to fill self-contained breathing apparatuses (SCBA) should be tested quarterly. The compressors air must be t ested for carbon dioxide, carbon monoxide, oxygen concentration and hydrocarbon condensate. Compressor air filters should be changed per the manufacturers guidelines. SCBAs should be inspected monthly. The units must be inspected for proper function and also to confirm that a minimum cylinder air capacity of 90% is maintained. Cylinders with air capacity falling below this level must be refilled.

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VIII. RECORDKEEPING
EH&S EH&S maintains respirator training and fit-testing records for all I SU employees certified by EH&S to be in the Respiratory Protection Program. These files include: Employee name and job description. Supervisor name and department. Anticipated respiratory hazards. Respirator type, manufacturer, model, size and approval number. Previous certification date (training and fit-testing). Type of agent used in fit-testing. Initials of person performing fit-testing.

Occupational Medicine Occupational Medicine will maintain the Medical Questionnaire for Respiratory Protective Equipment forms in G11 TASF. Supervisors Supervisors of employees voluntarily using dust mask respirators should maintain a record of employees given the Instructions for Voluntary Dust Mask Respirator Use at ISU policy.

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IX. PROGRAM EVALUATION

EH&S EH&S will periodically evaluate the ISU Respiratory Protection Program. EH&S will ensure that: Written respirator procedures exist. Records are complete for employee fit-tests and training. Employees have completed a medical evaluation prior to fit-testing. The written program is reviewed and updated to reflect necessary changes. Employees are surveyed on the effectiveness of the respiratory protection program during annual training.

Departments Departments are responsible for ensuring that: Employees have been trained in respirator use. Employees wear the correct respirators. Workplace hazards have been reviewed. Provisions of the written Respiratory Protection Program are implemented. Respirators and cartridges are properly maintained.

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APPENDIX A

Forms

Medical Questionnaire for Respiratory Protective Equipment Medical Approval for Respirator Use Respiratory Protective Equipment Recertification Medical Questionnaire Respirator Prescription

APPENDIX B

Instructions for Voluntary Dust Mask Respirator Use at Iowa State University

Instructions for Voluntary Dust Mask Respirator Use at ISU

The information on this sheet is intended for employees using respirators voluntarily and meets requirements outlined in Appendix D of OSHAs Respiratory Protection Standard 29 CFR 1910.134. Each employee using a dust mask respirator on a voluntary basis must be given a copy of this instruction sheet. Voluntary Respirator Use When airborne contaminant levels are below permissible levels (that is, they are essentially nonhazardous) respirator use at ISU is considered voluntary. If dust mask respirator use is voluntary, employees must complete the following: 1. Read and follow all instructions provided by the respirator manufacturer on use, maintenance, cleaning, care, and warnings regarding respirator limitations. Choose respirators certified by NIOSH (National Institute for Occupational Safety and Health). A label or statement of certification should appear on the respirator or respirator packaging. The label will indicate what the respirator is designed for and its limitations. All respirators available at ISU Central Stores meet NIOSH certification requirements. Do not wear respirators into atmospheres containing contaminants for which they are 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. Voluntary dust mask respirators should only be used for nuisance dusts. (DO NOT use them for lead, asbestos, cadmium, etc.) Dust mask respirators should only be used by their owner. Protect respirators from moisture, dust or other contaminants by storing them in plastic zip-lock bags or containers that can be sealed. Ensure that no objects are resting against stored respirators. This could damage the respirators, resulting in an improper fit when they are worn Destroy dust masks when discarded. Break straps or tear the respirators to make them unusable for anyone else.

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H:\GROUPS\IH\RESP\Voluntary Dust Mask Instructions-1998b.doc

APPENDIX C

Definitions

Acid Gas Cartridge: A respirator cartridge offering protection against acid gases such as sulfur dioxide, hydrochloric acid, hydrogen bromide, etc. The cartridge can also be used for organic vapors and/or chlorine (up to 10 ppm). (Note: Not all acid gases are removed by this cartridge. Consult with EH&S for limitations.) Air-Line Respirator (e.g., Type C supplied air respirator): The air-line respirator is connected to a suitable compressed air source which is delivered continuously or intermittently (pressure-demand). Typically this respirator type does not filter air but rather supplies clean air from a source outside the work area. Air Purifying Respirator: A respirator employing filters or cartridges to remove gases, mists, and/or particles from air (as opposed to air-supplying respirators). Dust Mask (dust/mist respirator): A respirator that filters dusts and mists but not gases (vapors). A dust mask not rated as HEPA will not filter out small dust particles such as t obacco smoke (0.01 - 1.0 micron diameter) or insecticide dust (approximately 0.5 - 10.0 micron diameter) and cannot be used for asbestos or lead related exposures. End-of-Service Life Indicators (ESLI): A system that warns the respirator user that respirator cartridges/filters are no longer effective. Fit Factor: Means a quantitative estimate of the fit of a particular respirator to a specific individual, and typically estimates the ratio of the concentration of a substance in ambient air to its concentration inside the respirator when worn. Full-Face Respirator: A respirator that fits over the eyes, nose and mouth, having a clear facepiece. Typically negative air purifying but includes SCBA and air-line as well. Half-Face Respirator: An air purifying respirator that fits over the mouth and nose, but not the eyes. Typically a negative air purifying respirator. HEPA: High Efficiency Particulate Air (filter) HEPA Filter Cartridge: A respirator cartridge that offers respiratory protection against airborne particulate matter including dusts, mists, metal fumes, and smokes; but not gases, vapors, or oxygen deficiency. Many HEPA filters are rated to capture over 99% of particles 0.3 microns in diameter or larger. HEPA filters and/or cartridges are typically used for protection against airborne asbestos, lead, radionuclides and other small diameter particulate air contaminants. HEPA cartridges are color coded with a purple/magenta band.

IDLH (Immediately Dangerous to Life or Health): An atmosphere that poses an immediate threat to life, would cause irreversible adverse health effects, or would impair an individuals ability to escape from a dangerous atmosphere. Air purifying respirators cannot be used in atmospheres above the IDLH of a contaminant. Maximum Use Concentration (MUC): The product of the protection factor (PF) of the respiratory protection equipment and the permissible exposure limit (PEL). (PF x PEL=MUC) Negative Air-Purifying Respirator: A respirator that fits tightly against the face and r elies on inhalat ion to bring air across filter cartridges to remove air contaminants. Organic Vapor Cartridge: A cartridge offering protection against organic gases and v apors such as hexane, naphtha, acetone, etc. (Note: Not all organic vapors are removed by this cartridge. Consult with EH&S for limitations.) OSHA: Occupational Safety and Health Administration PAPR (Powered Air Purifying Respirator): A PAPR uses a power source (usually a battery pack) to operate a blower that passes air across a filter, to supply purified air to a respiratory inlet. PEL (Permissible Exposure Limit): An exposure limit that is published and enforced by OSHA as a leg al standard. PELs are air contaminant concentrations at or below which a worker may continuously work 8 hours per day, 5 days per week, without ill effects. See also TLV. Protection Factor: The ratio of the ambient airborne concentration of a contaminant to its concentration inside the respirator. Half-face respirators are typically rated with a protection factor of 10, thus affording a 10-fold reduction in exposure when used properly. SCBA (Self Contained Breathing Apparatus): The type of respiratory protection typically used by fire fighters employing a compressed air tank and positive pressure or pressure-demand air regulators. TLV (Threshold Limit Value): A time weighted average air contaminant concentration under which most people can work continuously for eight hours a day , day after day, with no harmful effects. Unlike PELs, TLVs are updated regularly by the American Conference of Governmental Industrial Hygienists (ACGIH) and reflect current good practice exposure limits. Though they are similar to the PELs enforced by OSHA, TLVs are guidelines and ar e not enforceable under federal regulations. Qualitative Fit-Test (QLFT): It is a pass/fail fit-test to assess the adequacy of a respirator. It relies on the individuals response to the test agent.

Quantitative Fit-Test (QNFT): It is an assessment of the adequacy of respirator fit by numerically measuring the amount of leakage into the respirator. A specialized piece of equipment is used for this measurement.