Respiratory Protection Program Review Checklist [FREE PDF]

OSHA 29 CFR 1910.134 requires employers to establish a written respiratory protection program whenever respirators are necessary to protect employee health or are required by the employer. The standard mandates medical evaluations before respirator use, proper fit testing, training, and maintenance procedures. Deficiencies in respiratory protection programs are among OSHA's most frequently cited violations and can result in serious occupational lung disease.

  • Industry: Occupational Health
  • Frequency: Annually
  • Estimated Time: 50-70 minutes
  • Role: Occupational Health Nurse
  • Total Items: 36
  • Compliance: OSHA 29 CFR 1910.134 Respiratory Protection, OSHA 29 CFR 1910.1020 Access to Employee Exposure and Medical Records, NIOSH 42 CFR Part 84 Approval of Respiratory Protective Devices, ACGIH TLVs for Chemical Substances and Physical Agents, ANSI Z88.2 Practices for Respiratory Protection

Written Respiratory Protection Program

Verify that a compliant written program exists, is site-specific, and is administered by a designated program administrator.

  • Is a written respiratory protection program established and available at the worksite?
  • Does the written program identify a program administrator responsible for all aspects of the program?
  • Has the written program been updated within the past 12 months or after any significant change in respirator use?
  • Does the program address procedures for all worksites where respirators are used, including non-routine tasks?
  • Is the written program made available to all affected employees upon request?

Hazard Assessment & Respirator Selection

Confirm that a documented hazard assessment has been performed and appropriate respirator types are selected for identified hazards.

  • Has an industrial hygiene hazard assessment been conducted to identify all respiratory hazards in the workplace?
  • Are respirators selected based on identified hazards, anticipated employee exposure levels, and NIOSH approval?
  • Are assigned protection factors (APFs) used to ensure selected respirators provide adequate protection for measured exposure levels?
  • For IDLH (Immediately Dangerous to Life or Health) atmospheres, are SCBA or supplied-air respirators with egress capability used?
  • Are correct cartridge/filter types selected based on the specific chemical and physical nature of airborne hazards?

Medical Evaluation Program

Verify that medical evaluations are completed before initial respirator use and that records are properly maintained.

  • Are medical evaluations provided to all employees required to use respirators before initial fit testing or use?
  • Is the OSHA-required medical questionnaire (Appendix C to 1910.134) administered confidentially by the PLHCP?
  • Are follow-up medical examinations provided to employees whose initial questionnaire or evaluation results warrant additional evaluation?
  • Are medical evaluations repeated when employees report symptoms that may be related to respirator use?
  • Are medical evaluation records retained per OSHA 1910.1020 requirements and kept confidential?

Fit Testing

Assess whether fit testing is conducted correctly for all tight-fitting respirators using accepted qualitative or quantitative methods.

  • Are fit tests conducted for all employees using tight-fitting respirators before initial use?
  • Is fit testing repeated at least annually for all employees using tight-fitting respirators?
  • Are only OSHA-accepted qualitative (QLFT) or quantitative (QNFT) fit test protocols used?
  • Are fit test records maintained for each employee, including the specific respirator model, size, and test results?
  • Are employees who fail fit tests reassigned to a respirator model and size that achieves a passing result before use in hazardous areas?

Respirator Use Procedures

Confirm that employees follow correct procedures for donning, doffing, and using respirators in the field.

  • Do employees perform a user seal check (positive or negative pressure) each time a tight-fitting respirator is donned?
  • Are employees prohibited from wearing tight-fitting respirators when facial hair interferes with the facepiece seal?
  • Are employees permitted to leave the respirator use area when they need to wash their face or adjust the respirator?
  • For supplied-air and SCBA respirators, are emergency procedures documented and employees trained on emergency exit routes?
  • Is respirator use observed periodically in the field to ensure correct ongoing use and compliance?

Maintenance, Inspection & Storage

Review procedures for cleaning, inspecting, repairing, and storing respirators to maintain their protective integrity.

  • Are reusable respirators cleaned and disinfected after each use by an individual employee and before use by a different employee?
  • Are respirators inspected during cleaning and before and after each use for defects, tears, or degraded components?
  • Are defective respirators removed from service and repaired or discarded before being returned to use?
  • Are respirators stored in a manner that protects them from damage, contamination, dust, sunlight, and extreme temperatures?
  • Are SCBA cylinders inspected monthly and hydrostatic tested per DOT/manufacturer schedules?

Training & Program Evaluation

Confirm annual training is provided and that the program undergoes regular evaluation to verify its continued effectiveness.

  • Is training provided to all respirator users before initial use and at least annually thereafter?
  • Does training cover why the respirator is necessary, its capabilities, limitations, and proper use and maintenance?
  • Are training records (date, content, attendees) retained for at least 1 year?
  • Is a formal program evaluation conducted at least annually to assess program effectiveness?
  • Are deficiencies identified during program evaluations corrected within a documented timeframe?
  • Additional findings, corrective actions, or program notes?

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Why Use This Respiratory Protection Program Review Checklist [FREE PDF]?

This respiratory protection program review checklist [free pdf] helps occupational health teams maintain compliance and operational excellence. Designed for occupational health nurse professionals, this checklist covers 36 critical inspection points across 7 sections. Recommended frequency: annually.

Ensures compliance with OSHA 29 CFR 1910.134 Respiratory Protection, OSHA 29 CFR 1910.1020 Access to Employee Exposure and Medical Records, NIOSH 42 CFR Part 84 Approval of Respiratory Protective Devices, ACGIH TLVs for Chemical Substances and Physical Agents, ANSI Z88.2 Practices for Respiratory Protection. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Respiratory Protection Program Review Checklist [FREE PDF] cover?

This checklist covers 36 inspection items across 7 sections: Written Respiratory Protection Program, Hazard Assessment & Respirator Selection, Medical Evaluation Program, Fit Testing, Respirator Use Procedures, Maintenance, Inspection & Storage, Training & Program Evaluation. It is designed for occupational health operations and compliance.

How often should this checklist be completed?

This checklist should be completed annually. Each completion takes approximately 50-70 minutes.

Who should use this Respiratory Protection Program Review Checklist [FREE PDF]?

This checklist is designed for Occupational Health Nurse professionals in the occupational health industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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