When respirators are required, OSHA expects more than handing out masks. Here is how to run fit testing and medical evaluations without slowing the job.
In this article
When respirators are required
Silica, lead, asbestos and certain coatings can require respiratory protection.
Written program
A required respirator program needs a written plan covering selection, use and maintenance.
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Medical evaluation
Workers are evaluated before fit testing to confirm they can wear the respirator safely.
Fit testing
Each worker is tested with the exact make, model and size they will use.
Facial hair
Beards under the seal prevent a proper fit on tight-fitting respirators.
Training
How to put on, seal check, store and replace filters.
Records
Keep evaluations and fit test results organized and current.
Getting started
List the tasks that require respirators and schedule fit tests before the next project starts.
Common mistakes
Handing out masks without testing, ignoring facial hair and lost records.
Example
A drywall contractor scheduled fit tests for the whole crew before a large silica-heavy project. An inspection during the job found the program in order and no citations.
Annual cycle
Put fit test renewals on the same calendar as safety training. Schedule new hires before their first respirator task.
What to track
Workers fit tested, model and size, test date and next due date.
Talking with the crew
Explain that the test protects them, not the paperwork. Crews follow programs they understand.
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Frequently asked questions
Do workers need a fit test for a respirator?
When respirators are required, tight-fitting respirators generally need a medical evaluation and a fit test before use, repeated periodically and when the model or the worker's face changes. Follow OSHA's respiratory protection standard.