Respirator and Respiratory training for your employees is one of the most complex safety training topics.  Using safety videos in conjunction with the SafetyInfo Safety Library for training can help ensure you do not skip any required training.

Respirator training must be conducted in a manner that is understandable to the employee.  Also, respirator training must be provided prior to requiring an employee to use a respirator.

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Selecting the right respirator safety video depends on the type of respirators your employees need and environment in which they work.  If you have out-dated respirator safety videos, you may not be covering  all the essential topics required by OSHA.

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Employee respirator training must cover the following:

• OSHA Standard requirements

• Why  a respirator is needed

• Hazard identification

• Extent of exposures

• Potential health effects

• Selection of respirators

• Respirator inspection

• Donning procedure

• Removal procedure

• Fit Test and seal check

• Proper wearing

• Improper fit, usage, or maintenance effects

• Limitations and capabilities of the respirator

• Emergency situations

• Proper cleaning, maintenance & storage

• Symptoms & signs that may limit effective use

OSHA requires that employers provide effective training to employees who are required to use respirators. The training must be comprehensive, understandable, and recur annually, and more often if necessary. The employer shall ensure that each employee can demonstrate knowledge of at least the following:

Why the respirator is necessary and how improper fit, usage, or maintenance can compromise the protective effect of the respirator;

What the limitations and capabilities of the respirator are;

How to use the respirator effectively in emergency situations, including situations in which the respirator malfunctions;

How to inspect, put on and remove, use, and check the seals of the respirator;

What the procedures are for maintenance and storage of the respirator;

How to recognize medical signs and symptoms that may limit or prevent the effective use of respirators

Respirator retraining must  be administered annually, and when there are changes in the workplace or the type of respirator render previous training obsolete, inadequacies in the employee's knowledge or use of the respirator indicate that the employee has not retained the requisite understanding or skill; or any other situation arises in which retraining appears necessary to ensure safe respirator use.

OSHA’s respirator standard requires that employers establish and maintain an effective respiratory program—different hazards require different respirators—and employees are responsible for wearing the respirator and complying with the program.

Respirators must be used while effective engineering controls, if they are feasible, are being installed. If engineering controls are not feasible, employers must provide respirators, and employees must wear them when it is necessary to protect their health. The equipment issued to the employee must be properly selected, used, and maintained for a particular work environment and contaminant, and employees must be trained in all aspects of the respiratory protection program.

When planning a program to control occupational illness caused by breathing air contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, vapors, or sprays, the primary objective should be prevention.

Responsibility for the program must rest with one person. The program administrator must have sufficient knowledge of the subject to supervise the program properly. Larger plants or companies with industrial hygiene, health physics, plant medical department, safety engineering, or fire prevention departments should administer the program in liaison with the pro-gram administrator. In smaller plants that do not have industrial hygiene, health physics, safety engineering, or fire prevention departments, the program must be administered by an upper-level superintendent, foreman, or qualified person to be the responsible program administrator for the respirator program.

Any respirator program should stress thorough training of all users. Employees must be aware that the equipment does not eliminate the hazard. If the equipment fails, overexposure will occur. To reduce the possibility of failure, equipment must fit properly and be maintained in a clean and serviceable condition.

Employers and employees must understand the equipment’s purpose and its limitations. The equipment must not be altered or removed by the wearer even for a short time; despite the fact the wearer may find it uncomfortable.

An effective respirator program must cover the following factors:

• written worksite specific procedures;

• program evaluation;

• selection;

• training;

• fit testing;

• inspection, cleaning, maintenance and storage;

• medical evaluations;

• work area surveillance;

• air quality standards; and

• approved respirators.

When OSHA or employers require respirator use, employers are required to have written operating procedures for the safe and proper use of respirators. Users must be familiar with these procedures as well as with available respirators and their limitations. In workplaces with no hazardous exposures, but where there is voluntary respirator use, certain written program elements may be necessary to prevent potential hazards associated with respirator use.

Employers must evaluate whether respirator use itself may harm employees. If so, employers must medically evaluate employees and, if necessary, restrict use, as well as comply with program elements. Employers must inform employees voluntarily using respirators of basic information in Appendix D of OSHA’s Respiratory Protection standard.

The effectiveness of a company’s respirator program must be evaluated regularly and the written operating procedure modified as necessary to reflect the evaluation results. The use of a labor-management team may be effective for the periodic evaluation.

Choosing the Correct Respirators
Choosing the right equipment involves determining what the hazard is and its extent, choosing approved equipment, and ensuring that the device is certified. Equipment must be used pursuant to the conditions accompanying the certification.

Chemical and physical properties of the contaminant, as well as the toxicity and concentration of the hazardous material and the amount of oxygen present, must be considered in selecting the proper respirators. The nature and extent of the hazard, work rate, area to be covered, mobility, work requirements and conditions, as well as the limitations and characteristics of the available respirators also are selection factors.

Air-purifying respirators use filters or chemical absorbing canisters to remove harmful substances from the air. They range from simple disposable masks to sophisticated devices.

Air-purifying respirators do not supply oxygen and may not be used in oxygen-deficient atmospheres or in ones that are immediately dangerous to life or health (IDLH).

Atmosphere-supplying respirators are designed to provide breathable air from a clean air source other than the surrounding contaminated work atmosphere. They range from supplied-air respirators and self-contained breathing apparatus (SCBA) to complete air-supplied suits. The time needed to perform a given task, including the time necessary to enter and leave a contaminated area, is one factor that determines the type of respiratory protection needed. For example, SCBAs, gas-masks, or air-purifying chemical-cartridge respirators provide respiratory protection for relatively short periods whereas a type of atmosphere-supplying respirator that supplies breathable air from an air compressor through an airline can provide protection for extended periods of time. Particulate filter air-purifying respirators can provide protection for long periods without the need of filter replacement only if the total concentration of atmospheric particulates is low. Where there are higher concentrations of contaminants, however, an atmosphere-supplying respirator such as the positive-pressure supplied-air respirator (SAR) offers the advantage of better protection and longer duration. The use of SARs also avoids the need to be concerned about determining filter breakthrough times, change schedules, or using end-of-service-life indicators (ESLI) for airborne toxic materials, a factor that must be considered when using air-purifying respirators. SARs also cause less discomfort than air-purifying respirators because the wearer need not overcome filter resistance when inhaling.

Air-purifying respirators present minimal interference with the wearer’s movement. Atmosphere-supplying respirators, however, may restrict movement and present potential hazards.

For example, SARs with their trailing hoses, can limit the area the wearer can cover and may present a potential hazard where the trailing hose can come into contact with machinery. Similarly, an SCBA—a respirator that includes a back-mounted, compressed-air cylinder—presents both a size and weight penalty. This may restrict climbing and movement in tight places, and carrying the added weight of the air cylinder presents an additional burden. Another factor to consider when using respirators is the air-supply rates. The wearer’s work rate determines the volume of air breathed per minute. The volume of air supplied to meet the breathing requirements is of great significance when using atmosphere-supplying respirators such as self-contained and air-line respirators that use cylinders because this volume determines their operating life. The useful service life of these respirators under even moderate working conditions may be significantly less than under conditions of rest. The peak airflow rate also is important in the use of a constant-flow SAR. The air-supply rate should always be greater than the maximum amount of air being inhaled in order to maintain the respiratory enclosure under positive pressure.

Higher breathing resistance of air-purifying respirators under conditions of heavy work may result in distressed breathing. A person working in an area of high temperature or humidity is under stress. Additional stress, resulting from the use of a respirator, should be minimized by using one having a minimal weight and a minimal breathing resistance when these can be fitted properly to the wearer.

Some type of warning as to the remaining service is available for SCBAs and for some chemical canister respirators. This may be a pressure gauge or timer with an audible alarm for SCBAs or a color-end-of-service-life indicator (ESLI) on the cartridge or canister. The user should understand the operation and limitations of each type of warning device. Since many gas masks and chemical-cartridge respirators have no

ESLI indicators for their remaining service life, the employer or employee will need to do service life calculations. It is important, therefore, that new canisters and cartridges be used at the beginning of each work shift.

Fit Testing
Full facepieces, half masks, quarter masks and even the different brands of the same type of respirator marketed, have different fit characteristics. No one respirator will fit everyone. Employers need to have sufficient sizes and models available to achieve proper fit.

Corrective eyeglasses worn by employees also present a problem when fitting respirators. Special mountings are available to hold corrective lenses inside full facepieces. If corrective lenses are needed, the facepiece and lenses must be fitted by a qualified individual to provide good vision, comfort, and proper sealing.

The user must receive fitting instructions including demonstrations and practice in how to wear the respirator, how to adjust it, and how to determine if it fits properly.

Although respirators are designed for maximum efficiency, they cannot provide protection without a tight seal between the facepiece and the face of the wearer. Consequently, beards and other facial hair can substantially reduce the effectiveness of a respirator. The absence of dentures can seriously affect the fit of a facepiece. To ensure proper respiratory protection, a facepiece must be checked each time the respirator is worn. This can be accomplished by performing either a positive-pressure or negative-pressure user seal check. Detailed instructions for performing these tests can be found in Appendix B-1 of the OSHA standard.

The effectiveness of the fit of the facepiece can be tested two ways: qualitatively and quantitatively. Qualitative fit testing involves the introduction of a harmless odoriferous or irritating substance into the breathing zone around the respirator being worn. If no odor or irritation is detected by the wearer, a proper fit is indicated.

Quantitative fit testing offers more accurate, detailed information on respirator fit. It can involve introducing a harmless aerosol to the wearer while he or she is in a test chamber, the measurement of the ambient particulates in the air, or taking controlled negative-pressure measurements. While the wearer performs exercises that could induce facepiece leakage, the air inside and outside the facepiece is then measured for the presence of an aerosol, ambient particulates, or pressure change, to determine any leakage into the respirator.

Care of Respirators
All respirators must be inspected for wear and deterioration of their components before and after each use. Special attention should be given to rubber or plastic parts that can deteriorate. The face-piece, especially the face seal surface, headband, valves, connecting tube, fittings, and canister must be in good condition. A respirator inspection must include a check of the tightness of the connections.

SCBAs must be inspected at least monthly. Air and oxygen cylinders must be fully charged according to the manufacturer’s instructions. Regulator and warning devices must be checked to ensure their proper function. Records must be kept of inspection dates and findings. Chemical cartridges and gas mask canisters must be replaced as necessary to provide complete protection. The manufacturer’s recommendations must be followed. Mechanical filters must be replaced as necessary to avoid high resistance to breathing. Repairs must be made only by experienced persons using parts specifically designed for the respirator. The manufacturer’s instructions should be consulted for any repair, and no attempt should be made to repair or replace components or make adjustments or repairs beyond the manufacturer’s recommendations.

A respirator that has been used must be cleaned and disinfected before it is reissued. Emergency-use rescue equipment must be cleaned and disinfected immediately after each use.

Respirators must be stored to protect against dust, sunlight, heat, extreme cold, excessive moisture, or damaging chemicals. Protection against any mechanical damage also should be provided. Respirators should be stored so that facepieces and exhalation valves will rest in a normal position to prevent the rubber or plastic from reforming into an abnormal shape.

Respirators may be washed in a detergent solution and then disinfected by immersion in a sanitizing solution. Cleaner-sanitizers that effectively clean the respirator and contain a bactericidal agent are commercially available. The bactericidal agent frequently used is a quaternary ammonium compound. Strong cleaning and sanitizing agents and many solvents can damage rubber or elastic respirator parts. Such materials must be used with caution or after consultation with the respirator manufacturer.

Medical Evaluations
Persons assigned to tasks that require the use of a respirator must be physically able to perform the work while using the respirator. The local physician or licensed health care professional must determine what health and physical conditions are pertinent. The respirator user’s medical status must then be reviewed periodically. When respirators are worn in toxic atmospheres, the individual’s body burden may be evaluated using appropriate laboratory tests. These may include urine, blood, or fecal analysis and other techniques to determine the intake and excretion of toxic substances. The findings of these tests, when correlated with other exposure data, such as air sampling data for wearers of such equipment, can serve as an indication of the effectiveness of the program.

Positive evidence of exposure must be followed up with appropriate surveillance of work area conditions to determine if there is any relationship to inadequate respiratory protection or a need for additional engineering controls.

Surveillance must be maintained of the conditions in the work area and of the degree of worker exposure or stress (combination of work rate, environmental conditions, and physiological burdens of wearing a respirator). Changes in operating procedures, temperature, air movement, humidity, and work practices may influence the concentration of a substance in the work area atmosphere. These factors necessitate periodic monitoring of the air contaminant concentration. In instances where work is of such short duration that time to carry out the testing exceeds the time on the job, reasonable estimates of exposure are allowable.

In situations where the environment is or may be immediately dangerous to life or health (IDLH), employers must ensure that one employee or, when needed, more than one employee is located outside the dangerous environment and that visual, voice, or signal line communication is maintained between the employees in the IDLH atmosphere and employee(s) outside. In interior structural firefighting situations employers must ensure that at least two employees enter the structure and remain in visual or voice contact with one another at all times. Also, at least two employees shall be located outside to provide effective emergency rescue.

Equipment and Air-Quality Standards
Respiratory protective devices must be approved by the National Institute for Occupational Safety and Health (NIOSH), for the contaminant or situation to which the employee is exposed. Compressed air, compressed oxygen, liquid air, and liquid oxygen used for respiration must be of high purity. Oxygen must meet the requirements of the United States Pharmacopoeia for medical or breathable oxygen. Breathable air must meet at least the requirement for Grade D breathable air de-scribed in Compressed Gas Association (CGA) Commodity Specification G-7.1-1989.

Compressed oxygen must not be used in open circuit SCBAs or SARs that have previously used compressed air. Oxygen must never be used with airline respirators.

Breathable air may be supplied to respirators from cylinders or air compressors. For testing cylinders, see Shipping Container Specifications of the Department of Transportation (49 CFR Part 178). Containers of breathable gas must be clearly marked (see National Institute for Occupational Safety and Health, 42 CFR Part 84 requirements). Further details on the sources of com-pressed air and its safe use can be found in the CGA pamphlet G-7.1-1989, mentioned above.

The compressor for supplying air must be equipped with the necessary safety devices and alarms. Compressors must be constructed and situated to avoid any entry of contaminated air into the system and must be equipped with suitable in-line, air-purifying sorbent beds and filters installed to ensure air quality.

If an oil-lubricated compressor is used, it must have a high-temperature or carbon monoxide alarm or both. If only the high-temperature alarm is used, the air from the compressor must be tested frequently for carbon monoxide. Airline couplings must be incompatible with outlets for other gas systems to prevent accidental servicing of airline respirators with non-respirable gases or oxygen.

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