Chemical, Biological, 

Radiological, and 

Nuclear (CBRN) 

Respiratory Protection 

Handbook 
This page intentionally leftblank 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 

2 
 

 

 

 

 

 

 

This document is in the public domain and may be freely copied or reprinted 

DISCLAIMER 

Mention of any company or product does not constitute endorsement by the National Institute for 

Occupational Safety and Health, Centers for Disease Control and Prevention. In addition, citations to 

websites external to NIOSH do not constitute NIOSH endorsement of the sponsoring organizations or 

their programs or products. Furthermore, NIOSH is not responsible for the content of these websites. All 

web addresses referenced in this document were accessible as of the publication date. 

ORDERING INFORMATION 

To receive documents or other information about occupational safety and health topics, contact NIOSH: 

Telephone: 1-800-CDC-INFO (1-800-232-4636) 

TTY: 1-888-232-6348 

CDC INFO: www.cdc.gov/info 

or visit the NIOSH website at http://www.cdc.gov/niosh 

For a monthly update on news at NIOSH, subscribe to NIOSH eNews by visiting 

www.cdc.gov/niosh/eNews. 

SUGGESTED CITATION 

NIOSH [2018]. CBRN respiratory protection handbook. By Janssen L, Johnson AT, Johnson JS, Mansdorf 

SZ, Medici OR, Metzler RW, Rehak TR, Szalajda JV. Pittsburgh, PA: U.S. Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, DHHS (NIOSH) Publication No. 2018-166, https://doi.org/10.26616/NIOSHPUB2018166. 

DOI: https://doi.org/10.26616/NIOSHPUB2018166 

DHHS (NIOSH) Publication No. 2018-166 

July 2018 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 

3 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CBRN RESPIRATORY PROTECTION HANDBOOK 

ACKNOWLEDGEMENTS 

We would like to express our thanks and gratitude to the authors and editor of this 

handbook: 

Larry Janssen, MS, CIH, Respiratory Protection Consultant 

(chapters 4 and 9) 

Arthur T. Johnson, PhD, PE, Professor Emeritus, Bioengineering, University 

of Maryland (chapter 7) 

James S. Johnson, PhD, CIH, QEP, Industrial Hygiene Consultant, JSJ and 

Associates (chapters 5 and 6) 

S. Z. Mansdorf, PhD, CIH, CSP, QEP, Consultant (chapter 9) 

Osvaldo R. Medici, MEC E, MS Hygiene, Respiratory Protection 

Consultant (chapter 3) 

Richard W. Metzler, MSIE, Respiratory Protection Consultant 

(chapters 1, 2, and 3) 

Timothy R. Rehak, PE, NIOSH/NPPTL (chapters 1, 2, and 3) 

Jonathan V. Szalajda, MS, NIOSH/NPPTL (chapters 1, 2, and 3) 

Jordan Moore, MBA/MA, NIOSH/NPPTL (editor) 

We would like to thank the respirator manufacturers who provided NIOSH with pictures 

of their CBRN respirator products to be used as illustrations. We would also like to give 

special thanks to Chief Mark Aston of the Sonoma County Fire & Emergency Services 

Department in Santa Rosa, California and Lieutenant Greg Yeager of the Fort Collins 

Police Service in Fort Collins, Colorado for providing the current copies of their 

respiratory protection programs for inclusion in this handbook. Finally, the authors 

acknowledge the technical contributions and experience of Terrence Cloonan, 

BS, Physical Scientist, NIOSH, National Personal Protective Technology 

Laboratory drawn upon for providing background information related to the 

protection needs of the emergency response community. 

4 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CBRN RESPIRATORY PROTECTION HANDBOOK 

CONTENTS 

List of Acronyms 7 

Chapter 1 – Introduction 10 

Chapter 2 – NIOSH CBRN Respiratory Protective Device Approval Program 18 

• Approval of Respirators with CBRN Protection – RPD Types, Key Standards and Tests 

Chapter 3 – CBRN Respirator Equipment 43 

• CBRN Self-Contained Breathing Apparatus 

• CBRN Powered Air-Purifying Respirators 

• CBRN Air-Purifying Respirators 

• CBRN Air-Purifying Escape Respirators 

• Components for CBRN Air-Purifying Respirators 

• Air-Purifying Respirators 

• Maintenance and Storage of CBRN RPDs 

Chapter 4 – CBRN Respirator Selection 79 

• CBRN Self-Contained Breathing Apparatus 

• CBRN Powered Air-Purifying Respirators 

• CBRN Air-Purifying Respirators 

• CBRN Air-Purifying Escape Respirators 

• Components for CBRN Air-Purifying Respirators 

• Air-Purifying Respirators 

• Maintenance and Storage of CBRN RPDs 

Chapter 5 – CBRN Respiratory Protection Program Requirements 91 

• General Requirements 

• Procedures for Selecting Respirators for Use in a CBRN Response 

• Medical Evaluations of Employees Required to Use CBRN Respirators 

• Fit Testing Procedures for Tight-Fitting CBRN Respirators 

• Procedures for Proper Use of CBRN Respirators in Routine and Reasonable Foreseeable 

Emergency Situations 

• Procedures and Schedules for Cleaning, Disinfecting, Storing, Inspecting, Repairing, Discarding, 

and Otherwise Maintaining CBRN Respirators 

• Procedures to Ensure Adequate Air Quality, Quantity, and Flow of Breathing Air for AtmosphereSupplying CBRN Respirators 

• Procedures for Training 

• Procedures for Regularly Evaluating Effectiveness of the Program 

• Recordkeeping 

Chapter 6 – CBRN Respirator Fit Testing Methods 101 

• Respirator Fit Testing 

• Fit Test Methods 

• Qualitative Fit Test Methods 

• Quantitative Fit Test Methods 

• Fit Test Exercises 

• User Seal Check 

5 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CBRN RESPIRATORY PROTECTION HANDBOOK 

Chapter 7 – CBRN Equipment and the Wearer 109 

• The Nature of the Threat to Health 

• CBRN Equipment Effects 

• Control and Training Issues 

• Physiological Reponses to Work Activity 

• Physiological Limits 

Chapter 8 – Respirator Decontamination and Disposal 133 

• What is Contamination? 

• Types of Contamination 

• Effects of Contamination 

• Evaluation of Contamination 

• General Decontamination Approaches for Each Type of CBRN Agent 

• General Decontamination Approaches for CBRN Respirators 

• Decontamination Staging 

• Complicating Issues in Decontamination 

Chapter 9 – CBRN Respirator User Training 141 

• Regulations and Standards 

• Instructors 

• Specificity 

• Evaluation 

• Frequency 

• Records 

• Training Program Development Template 

Appendix A – CBRN Respirator Standards A-1 

Air-Purifying Respirators (APR) with CBRN Protection A-2 

Powered Air-Purifying Respirators (PAPR) with CBRN Protection A-17 

Air-Purifying Escape Respirators (APER) with CBRN Protection A-26 

Self-Contained Breathing Apparatus (SCBA) with CBRN Protection A-55 

Appendix B – OSHA CBRN Fit Testing Interpretation Letter B-1 

Appendix C – Respiratory Protection Program Samples C-1 

6 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

LIST OF ACRONYMS 

LIST OF ACRONYMS 

AEGL Acute Emergency Guideline Levels 

AHJ Authorities Having Jurisdiction 

ANSI American National Standards Institute 

APER Air-Purifying Escape Respirator 

APF Assigned Protection Factor 

APR Air-Purifying Respirator 

ASTM American Society for Testing and Materials 

ATP Adenosine Triphosphate 

ATSDR Agency for Toxic Substances and Disease Registry 

BSI British Standards Institution 

C&L Cautions and Limitations 

CAP Capacity 

CBRN Chemical, Biological, Radiological, and Nuclear [Hazards] 

CDC Centers for Disease Control and Prevention (HHS) 

CEN European Committee for Standardization 

CFR United States Code of Federal Regulations 

CO Carbon Monoxide 

COPD Chronic Obstructive Pulmonary Disease 

CS Tear Gas 

CWA Chemical Warfare Agent 

DHS U.S. Department of Homeland Security 

DOC U.S. Department of Commerce 

DoD U.S. Department of Defense 

DOE U.S. Department of Energy 

DOJ U.S. Department of Justice 

DOL U.S. Department of Labor 

DOP Dioctyl phthalate 

DOT U.S. Department of Transportation 

EMS Emergency Medical Services 

EN European Standards 

7 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

LIST OF ACRONYMS 

EPA Environmental Protection Agency 

EPDM Ethylene Propylene Diene Monomer 

ESLI End-of-Service-Life Indicator 

FF Fit Factor 

GA Tabun 

GB Sarin 

GD Soman 

HAZWOPER OSHA’s Hazardous Waste Regulation (29 CFR 1910.120) 

HD Distilled Sulfur Mustard [Chemical Warfare Agent] 

HHS U.S. Department of Health and Human Services 

HR Hazard Ratio 

IAB InterAgency Board for Equipment Standardization and Interoperability 

IAFC International Association of Fire Chiefs 

IAFF International Association of Fire Fighters 

IDLH Immediately Dangerous to Life or Health 

ISEA International Safety Equipment Association 

ITF International Task Force 

LAT Live Agent Test 

LERL 1 Law Enforcement Response Level 1 

Li-ion Lithium Ion 

LiMnO2 Lithium-Manganese Dioxide 

LiSO2 Lithium-Sulfur Dioxide 

LPM Liters per Minute 

LRPL Laboratory Respirator Protection Level 

MIPT Memorial Institute for the Prevention of Terrorism 

(Oklahoma City) 

MOU Memorandum of Understanding 

MPC Minimum Packaging Configuration 

MRT Modified Rhyme Test 

MSHA Mine Safety and Health Administration 

NFPA National Fire Protection Association 

NIJ National Institute of Justice 

NiMH Nickel-Metal Hydride 

NIOSH National Institute for Occupational Safety and Health 

(HHS/CDC) 

8 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

LIST OF ACRONYMS 

NIST National Institute for Standards and Technology (DOC) 

NPPTL National Personal Protection Technology Laboratory 

(HHS/CDC/NIOSH) 

ODP Office for Domestic Preparedness (DOJ) 

OEL Occupational Exposure Limit 

OJP Office of Justice Programs (DOJ) 

OSHA Occupational Safety and Health Administration (DOL) 

PAPR Powered Air-Purifying Respirator 

PEL Permissible Exposure Limit 

PLHCP Physician or Other Licensed Health Care Professional 

PPE Personal Protective Equipment 

QLFT Qualitative Fit Test 

QNFT Quantitative Fit Test 

RDECOM Research, Development, and Engineering Command (USARMY) 

REL Recommended Exposure Limit 

RFT Respirator Fit Test 

ROP Report on Proposals [NFPA Standards Terminology] 

RPD Respiratory Protective Device 

SAR Supplied-Air Respirators 

SCBA Self-Contained Breathing Apparatus 

SEI Safety Equipment Institute 

SOG Standards, Objectives, and Goals 

SOP Standard Operating Procedure 

TG Technical Guide 

TIC Toxic Industrial Chemicals 

TLV© Threshold Limit Value 

TRA Test Representative Agent 

USACHPPM U.S. Army Center for Health Promotion and Preventive Medicine 

VAS Visual Acuity Score 

VX O-ethyl S-[2-(diisopropylamino)ethyl] methylphosphonothioate 

WTC World Trade Center 

Zn/MnO2 Alkaline zinc-manganese dioxide 

9 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

CHAPTER 1 – 

INTRODUCTION 

Authors: Richard W. Metzler; Jonathan V. Szalajda; and Timothy R. Rehak 

The Handbook Objective 

Since 2001, the U.S. Department of Health and Human Services (HHS), Centers for Disease Control and 

Prevention (CDC), National Institute for Occupational Safety and Health (NIOSH) has established 

performance and design standards for respiratory protective devices (RPDs) to protect against chemical, 

biological, radiological, and nuclear (CBRN) hazards and toxic industrial chemicals. Prior to 2001, there 

were no standards for the use of RPDs by U.S. emergency response personnel that covered the full range 

of expected CBRN threats. Federal regulations require emergency response personnel to use respirators 

approved by NIOSH for the expected hazards. Equipment performance standards were needed to 

protect against CBRN threats. Neither industrial nor military respirators provided protection from all 

potential CBRN respiratory hazards. Several federal agencies partnered to provide research and testing 

to produce the necessary standards: Department of Justice (DOJ); Department of Homeland Security 

(DHS); Department of Defense (DoD), U.S. Army Research, Development and Engineering Command 

(RDECOMa

); Department of Commerce (DOC), National Institute for Standards and Technology (NIST); 

and the Department of Labor (DOL), Occupational Safety and Health Administration (OSHA). 

The NIOSH RPD approval standards and tests developed for CBRN protections are highly specialized. The 

advanced CBRN respirators have unique characteristics related to selection, use, and maintenance 

compared to NIOSH-approved industrial respirators. Due to the enhanced protection afforded by NIOSHapproved CBRN respirators, it is likely that the respirators will also be used in industrial applications. 

Nationally prominent organizations have identified the need for advice and training on CBRN respirators. 

Among these are the RAND Corporation, Science and Technology Policy Institute, and the Federal 

InterAgency Board (IAB) for Equipment Standardization and Interoperability. Responders in several 

RAND studies clearly expressed the need for guidelines related to personal protective equipment (PPE), 

including respirators [Bartis et al. 2005; Jackson et al. 2002; Jackson et al. 2004; LaTourrette et al. 2003; 

Willis et al. 2006]. As early as 2002, RAND reported: 

One of the clear messages of the conference (December 10, 2001) was that most emergency workers do not 

believe that they are prepared with the necessary information, training, and equipment to cope with many 

of the challenges associated with the response to a major disaster such as the World Trade 

Center attack or for threats associated with anthrax, and similar agents [Jackson et al. 

2002]. 

Another RAND study indicated: 

In sum, community representatives stressed that a greater amount of training and education 

must be part of any policy to improve the protection of emergency responders in the line of 

duty [LaTourrette et al. 2003]. 

a Formerly U.S. Army Soldier and Biological Chemical Command (SBCCOM) 

10 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

An IAB annual report also underscored the need for guidance: 

The emergency responder community has a need for guidance and information on the selection, use, and 

maintenance of CBRN respirators to ultimately reduce incidences of respiratory related injury for nearly 4 

million career and volunteer corrections, emergency medical services, firefighting, and law enforcement 

responders [IAB 2009]. 

This handbook fills the critical need for authoritative technical information on CBRN RPDs. The 

information presented will assist any user of CBRN respirators to improve selection, use, and 

maintenance, but it is particularly useful to those individuals responsible for administering respirator 

protection programs or developing training programs. 

The handbook is intended for organizations that use CBRN respirators in emergency response 

applications (e.g., fire service, law enforcement, emergency medical services, and corrections officers). It 

does not include information on how to conduct response activities. Others who use CBRN respirators in 

industrial, public works, construction, utility, and other non-emergency applications will also benefit from 

the information presented. 

The information in the following chapters can be used to develop a more effective CBRN respiratory 

protection program and establish effective training programs in support of other requirements such 

as relevant National Fire Protection Association (NFPA) and OSHA standards. Relevant NFPA standards 

include NFPA 472 (Standard for Competence of Responders to Hazardous Materials/ Weapons of Mass 

Destruction Incidents) and NFPA 473 (Standard for Competencies for EMS Personnel Responding to 

Hazardous Materials/Weapons of Mass Destruction Incidents). Relevant OSHA and EPA standards 

include Title 29 Code of Federal Regulations (CFR) 1910.134 (Respiratory Protection) and 1910.120 

(Hazardous Waste Operations and Emergency Response), and Title 40 CFR Chapter 1, Part 311 (Worker 

Protection). 

The Need for Special CBRN RPD Standards and

Tests – Pre-September 11, 2001 

From March 10-12, 1999, NIOSH, RDECOM, and OSHA jointly sponsored a technical workshop to explore 

potential hazards, respiratory protection needs, respiratory protective device standards, and public 

health and medical community concerns associated with chemical and biological terrorism and other 

crisis situations. The workshop was one of the first national forums to systematically identify emergency 

responders and define their respiratory protection needs [NIOSH 2000]. 

More than 140 representatives from 63 emergency responder, fire fighter, domestic preparedness, 

equipment manufacturing, federal research, and state and federal regulatory organizations participated. 

This workshop marked the beginning of NIOSH standards development activities to add CBRN protection 

to several respirator classes. 

Earlier that same year, the International Association of Fire Chiefs (IAFC) asked NIOSH if a NIOSHapproved, NFPA- compliant, self-contained breathing apparatus (SCBA) would protect firefighters 

against chemical and biological warfare agents. NIOSH did not know the answer, but suspected that the 

apparatus would not provide the needed protection: Neither NIOSH (42CFR84) nor NFPA RPD standards 

included an SCBA performance evaluation against CBRN agents. The IAFC and International Association 

of Fire Fighters (IAFF) urged NIOSH to provide leadership to bring appropriate military, safety, and health 

experts together to answer this question and develop the standards necessary to protect the nation’s 

emergeny responders. 

11 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

In response, NIOSH established partnerships with organizations whose expertise and resources were 

required to address the gaps in knowledge, technology, standards, and training. The principal federal 

agencies that collaborated with NIOSH were: 

Department of Justice (DOJ), Office of Justice Programs (OJP), Office for Domestic Preparedness 

(ODP) 

Department of Commerce (DOC), National Institute of Standards and Technology (NIST) 

Department of Defense (DoD), U.S. Army, Research, Development, and Engineering Command 

(RDECOM) 

Department of Labor (DOL), Occupational Safety and Health Administration (OSHA) 

Other organizations whose support was essential for the successful development and implementation 

of the NIOSH CBRN RPD standards were: 

International Association of Fire Chiefs (IAFC) 

International Association of Fire Fighters (IAFF) 

International Safety Equipment Association (ISEA) 

Memorial Institute for the Prevention of Terrorism (MIPT) (Oklahoma City) 

National Fire Protection Association (NFPA) 

The collaboration with NIST and RDECOM was of foremost importance. NIST administered federal funds 

made available from the DOJ and made these resources available to substantially finance the research 

and technical activities required to develop new standards. RDECOM applied its expertise with military 

warfare agents and its highly specialized laboratories to conduct respirator evaluations, CBRN hazard 

assessments of possible chemical warfare agent (CWA) incidents, and analyses of human factor 

requirements. 

The hazard assessment considered physical chemistry characteristics, vapor pressure-based saturation 

estimates, and use of terrorism venue modeling techniques to generate information about potential 

hazards at an incident involving CWAs. For these assessments, RDECOM considered the means of 

delivery and dissemination (i.e., explosion, spill, spray) of the CWA combined with other variables, 

including the amount of CWA (i.e., small containers, large drums) and the environmental and physical 

characteristics of the area where the incident occurs (i.e., small rooms, large shopping centers, airport 

concourses). RDECOM also modeled conditions related to climate control (air circulation, etc.) for 

the various incident sites. A team of experts from the collaborating agencies agreed upon the potential 

exposures. 

Hazards and test procedures were established based upon exposure projections. SCBAs approved by 

NIOSH and NFPA standards were evaluated. The initial benchmark test results answered the key 

question raised by the IAFC: It was clear that new standards and test procedures were needed to 

enhance industrial SCBA performance by adding CBRN protection. Thus, the NIOSH standards 

development process began with a sense of urgency. 

A multi-agency CBRN Standards Development Team was established. The team began development 

efforts to define an appropriate set of performance and design standards for respiratory protective 

equipment with CBRN protection in July 2000. 

12 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

The Need for Special CBRN RPD Standards and Tests – Lessons

Learned from 9/11 

Before completion of the first series of CBRN respirator standards, the nation and world were stunned by 

the devastating terrorist attacks on the World Trade Center complex and the Pentagon, and the crash of 

United Airlines flight 93 over Pennsylvania on September 11, 2001. Fortunately, these attacks did not 

involve the deliberate use of CBRN agents against the U.S. population, and respirators with highly 

specialized CBRN protection were not required for the response. However, the message was clear: New 

standards and NIOSH-approved CBRN RPDs were needed. 

Along with the ongoing CBRN RPD standards development process, NIOSH commissioned a series of 

studies with the RAND Corporation to identify gaps in PPE and RPD technology, standards, and training. 

The first of these studies involved lessons learned from terrorist attacks. To this end, NIOSH and RAND 

held a conference in New York City from December 9–11, 2001. Attendees included persons who 

responded to the 1995 attack on the Alfred P. Murrah Federal Building in Oklahoma City, the September 

11 attacks on the World Trade Center and the Pentagon, and the anthrax incidents that occurred in 

autumn of 2001. The first of four studies published by NIOSH and RAND provided key information about 

the shortcomings of PPE and RPDs used for large-scale, complex tasks having long duration [Jackson et 

al. 2002]. 

The studies revealed the needs for an integrated respiratory protection program, RPD equipment 

standardization, and interoperable use of facepieces and air-purifying components. These findings were 

incorporated into the CBRN RPD standards development process. For example, the standards 

established for CBRN air-purifying respirators (APRs), also known as CBRN gas masks, included special 

design requirements to ensure that all NIOSH-approved CBRN APR facepieces and filtering components 

(canisters), regardless of manufacturer, could be used together during an emergency and still provide the 

NIOSH-defined necessary level of CBRN protection. An interoperability requirement was added to 

address the respirator component supply shortages that occurred at the World Trade Center response 

operation. In September 2001, only components of a NIOSH-approved complete respirator assembly, as 

defined in the NIOSH certificate of approval, were permissible even when components from other 

manufacturers’ respirators of the same type were available. The lack of availability of some components 

during the extended World Trade Center response may have reduced the equipment available to 

workers and caused delays in response activities while the proper components were obtained, alternate 

respirators were employed, and proper retraining was provided. Other findings noted the need for RPDs 

with scratch resistant lenses, improved field of view, upgraded communications accessories, and more 

durable components for use in arduous environments. 

The aftermath of the terror attacks revealed the need for escape respirators for public use during 

emergencies. Workers in buildings and private citizens may also need to evacuate the scene of a terror 

attack. In addition to the types of RPDs used by emergency responders, the multi-agency team added 

escape respirators to the list of RPDs that required enhanced standards and tests for CBRN protection. 

CBRN Standards and Test Development and Implementation 

The multi-agency team held joint public meetings and solicited public comments via NIOSH Docket-002 

concerning standards and test requirements for SCBAs with CBRN protection (commonly referred to 

as CBRN SCBAs). Through this public process and the RDECOM testing, NIOSH identified the 

performance and design requirements desired in CBRN SCBAs. 

13 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

NIOSH determined that all requirements could be met if the following standards and tests were applied: 

Title 42, CFR, Part 84 (42CFR84); NFPA Standard 1981 for Open-Circuit Self-Contained Breathing 

Apparatus for Fire Fighters; and special tests including Chemical Agent Permeation and Penetration 

Resistance Against Sarin (GB) and Distilled Mustard Sulfur (HD), and Laboratory Respiratory Protection 

Level (LRPL). 

On December 28, 2001, NIOSH issued a letter to all interested parties, notifying them of the acceptance 

of applications for the testing and evaluation of Self-Contained Breathing Apparatus for use against 

CBRN agents [NIOSH 2001]. These standards were adopted in 2003 by the IABb and incorporated into the 

Department of Homeland Securityc grants program. 

CBRN RPDs and CBRN SCBAs were the first respirators used in non-military applications with protection 

against a broad range of chemical warfare agents, toxic industrial chemicals, and biological hazards. 

Subsequently, standards and tests were also developed and implemented for air-purifying respirators 

(APRs), powered air-purifying respirators (PAPRs), and air-purifying escape respirators (APERs) [NIOSH 

2003a,b, 2006]. 

The NIOSH standards development and respirator certification programs led to an increase in the 

national inventory of CBRN protection for emergency response personnel. This will better protect 

emergency responders against a variety of respiratory hazards. Multiple models of respirators from 

several manufacturers have been certified to the CBRN respirator standards. Additional information on 

approval models is available through the NIOSH/NPPTL web site: https://www.cdc.gov/niosh/npptl. 

The CBRN respirator standards have been endorsed and incorporated by DHS, NFPA, and the IAB. The 

performance requirements for CBRN respirators are being included in the development of international 

standards (British Standards Institution). DHS grants now link to the CBRN Respirator Performance 

Standards. 

It also became clear that improved information and training on RPD selection, use, and maintenance 

was needed to address unique characteristics of CBRN RPDs. The information contained in this 

handbook will be useful in providing support to establish training programs compliant with: 

NFPA 472 (Standard for Competence of Responders to Hazardous Materials/ Weapons of Mass 

Destruction Incidents) 

NFPA 473 (Standard for Competencies for EMS Personnel Responding to Hazardous 

Materials/Weapons of Mass Destruction Incidents) 

OSHA and EPA standards, including Title 29 CFR 1910.134 (Respiratory Protection) and 1910.120 

(Hazardous Waste Operations and Emergency Response), and Title 40 CFR Chapter 1, Part 311 

(Worker Protection) 

More information about the standards and test procedures established for CBRN respirators may be 

found on the NIOSH website at: https://www.cdc.gov/niosh/npptl/respmanuf. 

The listing of all respirators approved by NIOSH that contain CBRN protection can be found on the NIOSH 

website at: https://www.cdc.gov/niosh/npptl/topics/respirators/CEL. 

b Sanctioned by the Attorney General of the United States, the InterAgency Board for Equipment Standardization 

and Interoperability (IAB) was founded by the Department of Defense Consequence Management Program Integration Office and the 

Department of Justice Federal Bureau of Investigation Weapons of Mass Destruction Countermeasures program on October 13, 1998. The 

mission objectives related to personal protective equipment were being drafted at the time of the NIOSH-DoD-OSHA sponsored Chemical and 

Biological Respiratory Protection Workshop, March 10–12, 1999. c On July 16, 2002, U.S. President George W. Bush established the Office of Homeland Security. The Homeland Security Act of 2002 established 

the Department of Homeland Security on November 25, 2002. It consolidated U.S. executive branch organizations related to homeland security 

into a single Cabinet agency. 

14 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

A Word About the Other Chapters 

Chapter 2 – NIOSH CBRN Respiratory Protective Device Approval Program provides a description of the 

NIOSH RPD approval program and the highly specialized performance and design standards and unique 

test procedures that ensure an RPD has CBRN protection capability. Understanding the standards and 

tests applicable to CBRN RPDs (including SCBAs, APRs, PAPRs, and APERs) provides knowledge about the 

respirators’ cautions and limitations. Knowledge can be applied to establish an effective respiratory 

protection program and training programs tailored to the intended user when used with the specific 

instructions provided by the manufacturer and NIOSH approval labels. 

Chapter 3 – CBRN Respirator Equipment introduces CBRN equipment. This chapter presents information 

for each CBRN RPD class, including information on the major components, uses and limitations, markings 

and labels, maintenance, and storage requirements. It also describes common uses of the RPD class and 

pictures to illustrate key characteristics of the respirators. For example, when it comes to CBRN PAPRs, 

special emphasis is placed on information related to battery care. This chapter also describes the 

characteristics of the RPD that meet the CBRN standards and test requirements. 

Chapter 4 – CBRN Respirator Selection provides key information about characterization of hazards and 

appropriate selection of CBRN RPDs. This chapter describes the steps required in a selection process, 

including knowledge of the hazard, workplace considerations, human factors, and the performance 

capabilities of the CBRN RPD. A decision logic flowchart provides further direction. 

Chapter 5 – Respiratory Protection Program Requirements provides background information on the 

importance of a complete program. It integrates information from Chapters 1 and 2 for administering 

the selection, use, and care of respirators in the workplace. This chapter describes the required elements 

of OSHA and the American National Standards Institute compliant programs. Sample programs provide 

examples and illustrate the diversity and level of detail typically found in compliant programs. 

Chapter 6 – CBRN Respirator Fit Testing Methods provides a short history of fit testing and 

demonstrates the value of testing the fit of a respirator to each specific individual to ensure proper 

performance. This chapter covers the purpose of fit testing, frequency, various fit test methods, and 

exercises. Information about the qualifications of the fit test operator and record keeping is also 

presented. 

Chapter 7 – CBRN Equipment and the Wearer provides fundamental information related to human 

physiology and aspects of respirator performance that affect a person’s ability to wear CBRN RPDs. CBRN 

respirators and protective clothing are designed, assembled, and tested to ensure they meet the level of 

protection that first responders and ancillary personnel require to respond appropriately and safely to 

the emergency. Topics include the effects of breathing resistance, work rate/ breathing ventilation rates, 

and tolerance to carbon dioxide build up in the respirator. Knowledge of the physiological impact can aid 

in the selection and use of CBRN RPDs. 

Chapter 8 – Respirator Decontamination and Disposal provides information about the various 

decontamination methods, cautions, and limitations. Decontamination is important for avoiding cross 

contamination, potentially allowing reuse of equipment that is expensive and difficult to replace, and 

properly disposing of contaminated PPE. In every case, decontamination must be performed to allow for 

the safe removal of the protective ensemble. Decontamination approaches depend on many factors 

including the protective ensemble used, the known or suspected CBRN agent, the available 

decontamination resources, and the urgency of the situation. 

15 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 1 

INTRODUCTION 

Chapter 9 – CBRN Respirator User Training describes the goals and importance of training programs and 

provides information to help establish effective training for respirator users. The NIOSH respirator 

approval program ensures CBRN respirators are capable of protecting users from a wide range of 

potential hazards, but the expected level of protection cannot be achieved if users do not use the 

respirators properly. Initial and ongoing training are necessary to ensure each user is able to don and 

wear the respirator and other protective equipment while performing assigned duties. This chapter also 

describes the minimum requirements for achieving compliance with OSHA and NFPA standards. 

References 

Bartis JT, Jackson BA, LaTourrette T [2005]. Technical source document: personal protective equipment 

R&D roadmap, firefighting and hazardous materials response. Santa Monica, CA: RAND Corporation. 

IAB [2009]. InterAgency Board 2008 annual report and 2009 standardized equipment list. Arlington, VA: 

InterAgency Board https://www.hsdl.org/?view&did=31234. 

Jackson BA, Baker JC, Ridgely MS, Bartis JT, Linn HI [2004]. Protecting Emergency Responders, volume 3: 

safety management in disaster and terrorism response. Vol 3. Santa Monica, CA: RAND Corporation. 

Online at http://www.rand.org/publications/MG/MG170. 

Jackson BA, Peterson D. J., Bartis JT, LaTourrette T, Brahmakulam IT, Houser A, Sollinger JM [2002]. 

Protecting Emergency Responders: lessons learned from terrorist attacks. Vol, 1. Santa Monica, CA: 

RAND Corporation. Online at http://www.rand.org/publications/CF/CF176. 

LaTourrette T, Peterson D.J., Bartis JT, Jackson BA, Houser A [2003]. Protecting Emergency Responders, 

volume 2: community views of safety and health risks and personal protection needs. Vol 2. Santa 

Monica, CA: RAND Corporation. Online at 

https://www.rand.org/pubs/monograph_reports/MR1646.html. 

NIOSH [2000]. NIOSH-DOD-OSHA sponsored chemical and biological respiratory protection workshop 

report. By Dower JM, Metzler RW, Palya FM, Peterson JA, Pickett-Harner M. Washington, DC: U.S. 

Department of Health and Human Services, Centers for Disease Control and Prevention, National 

Institute for Occupational Safety and Health, DHHS (NIOSH) Publication No. 2000-122, 

https://www.cdc.gov/niosh/docs/2000-122/. 

NIOSH [2001]. Letter to all interested parties. Acceptance of applications for the testing and evaluation 

of self-contained breathing apparatus for use against chemical, biological, radiological, and nuclear 

agents. By Metzler RW, Acting Director, National Personal Protective Technology Laboratory. December 

28, 2001. Pittsburgh, PA: US Department of Health and Human Services, Centers for Disease Control and 

Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/resources/pressrel/letters/lttr-122801.html. 

NIOSH [2003a]. Statement of standard for full facepiece air purifying respirators (APR). Pittsburgh, PA: 

US Department of Health and Human Services, Centers for Disease Control and Prevention, National 

Institute for Occupational Safety and Health, http://ddq74coujkv1i.cloudfront.net/pdfs/NIOSHstandard-for-gas-masks.pdf. 

16 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

CHAPTER 1 

INTRODUCTION 

NIOSH [2003b]. Statement of standard for chemical, biological, radiological, and nuclear (CBRN) airpurifying escape respirator. Pittsburgh, PA: US Department of Health and Human Services, Centers for 

Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/standardsdev/cbrn/escape/standard/pdfs/cbrn-esc-att-a.pdf. 

NIOSH [2006]. Statement of standard for chemical, biological, radiological, and nuclear (CBRN) powered 

air-purifying respirators (PAPR). Pittsburgh, PA: US Department of Health and Human Services, Centers 

for Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/pdfs/CBRNPAPR/CBRNPAPRStatementofStandard.pdf. 

Willis HH, Castle NG, Sloss EM, Bartis JT [2006]. Protecting Emergency Responders: personal protective 

equipment guidelines for structural collapse events. Vol 4. Santa Monica, CA: RAND Corporation. Online 

at http:// www.rand.org/publications/MG/MG425). 

17 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

CHAPTER 2 – 

NIOSH CBRN RESPIRATORY PROTECTIVE 

DEVICE APPROVAL PROGRAM 

Authors: Richard W. Metzler; Jonathan V. Szalajda; and Timothy R. Rehak 

Introduction 

The U.S. Department of Health and Human Services (HHS), Centers for Disease Control and Prevention 

(CDC), National Institute for Occupational Safety and Health (NIOSH) administers Title 42, Code of 

Federal Regulations (CFR), Part 84 (42CFR84), rules for approval of respiratory protective devices (RPDs). 

This administrative authority is jointly held by the U.S. Department of Labor (DOL), Mine Safety and 

Health Administration (MSHA) for RPDs used for mine rescue and other mine emergencies, as defined in 

the Memorandum of Understanding (MOU) between MSHA and NIOSH [Approval of respiratory 

protective devices, 1995]. 

42CFR84 specifies the mandatory minimum requirements NIOSH uses in conducting inspections, 

examinations, and tests to determine the effectiveness of respirators used during entry into or escape 

from hazardous atmospheres (§84.1[d]). It also outlines the requirements for applications for approval 

fees, packaging labels, product markings, respirator general construction and performance, and quality 

assurance. These minimum design, performance, test, and quality assurance standards define the 

protection levels of various types of respirators approved by NIOSH. 

NIOSH-approved respirators are classified (§84.50) by the standards and testing requirements described 

in 42CFR84 Subparts G through L, N, O, and KK. These requirements have been found to provide 

respiratory protection for fixed periods of time against the hazards specified in the approval. The 

following are common types of respirators for which NIOSH prescribes requirements in 42CFR84: selfcontained breathing apparatus (SCBAs) (Subpart H); gas masks (Subpart I); supplied-air respirators (SARs) 

(Subpart J); non-powered air-purifying particulate respirators (Subpart K), and chemical cartridge nonpowered air-purifying respirators (APRs) and powered air-purifying respirators (PAPRs) (Subpart L, KK); 

combination respirators with gas, vapor and/or particulate (various Subparts); special use respirators 

such as vinyl chloride respirators (Subpart N); and closed-circuit escape respirators (Subpart O). 

NIOSH inspects and examines respirators and approval application content (technical specifications, 

drawings, user instructions), and tests respirators to determine that the applicable requirements are met 

for individual, completely assembled respirators, described in §84.30(a). Certificates of approval are 

issued to an RPD that meets the applicable requirements of 42CFR84. Certificates of approval are not 

issued for any individual respirator components (§84.30[b]). Each certificate of approval includes labels 

to be used by the applicant with each approved respirator assembly (§84.31[d]). Use of the NIOSH label 

obligates the applicant to whom it was issued to maintain the quality level of manufactured respirators 

and assure the RPD is manufactured to the drawings and specifications upon which the certificate of 

approval is based (§84.33[f]). 

18 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

In addition to those requirements, NIOSH: 

Conducts post-approval audits of respirators to assure they are produced in accordance with the 

manufacturer’s product specifications as described in the approval records maintained by NIOSH 

Conducts post-approval manufacturing site audits to ensure the manufacturer’s quality assurance 

system is as described in the approval records maintained by NIOSH 

Investigates complaints related to a respirator conforming to the certificate of approval, including 

NIOSH standards, performance, design, product and packaging markings, and test requirements 

Investigates conformity to NIOSH standards and test requirements of respirators involved in injuries 

and fatalities, when requested to do so 

Issues public notices such as safety alerts and announcements of respirator recalls or retrofits, or the 

revocation of the NIOSH certificate of approval 

Information about the NIOSH RPD approval program—including lists of NIOSH-approved respirators 

(referred to as the NIOSH Certified Equipment List(CEL)), NIOSH public announcements concerning 

approved respirators, standard test procedures for each RPD type, and other investigative reports—are 

available on the NIOSH, National Personal Protective Technology Laboratory (NPPTL) website: 

https://www.cdc.gov/niosh/npptl. 

Approval of Respirators with CBRN Protection – RPD Types, 

Key Standards and Tests 

RPD Types 

NIOSH has only limited authority and flexibility specified in 42CFR84 (§84.60[b], §84.63[c], and 

§84.110[c]) to approve types of respirators not prescribed in 42CFR84, such as respirators for protection 

against chemical, biological, radiological, and nuclear (CBRN) hazards. These sections provide NIOSH with 

the limited authority to develop additional requirements that the agency determines are “necessary to 

establish the quality, effectiveness and safety of any respirator used as protection against hazardous 

atmospheres.” 

These sections specify: 

84.60(b) – “In addition to the types of respirators specified in subparts H through L of this part, 

the Institute shall issue approvals for other respiratory protective devices not specifically described 

in this part subject to such additional requirements as may be imposed in accordance with 84.63(c).” 

84.63(c) – “In addition to the minimum requirements set forth in subparts H through L of this part, 

the Institute reserves the right to require, as a further condition of approval, any additional 

requirements deemed necessary to establish the quality, effectiveness, and safety of any respirator 

used as protection against hazardous atmospheres.” 

84.110(c) – “Gas masks for respiratory protection against gases and vapors other than those 

specified in paragraph (b) of this section, may be approved upon submittal of an application in 

writing for approval to the Certification and Quality Assurance Branch listing the gas or vapor and 

suggested maximum use concentration for the specific type of gas mask. The Institute will consider 

the application and accept or reject it on the basis of effect on the wearer’s health and safety and 

any field experience in use of gas masks for such exposures. If the application is accepted, the 

Institute will test such masks in accordance with the requirements of this subpart” [Approval of 

respiratory protective devices, 1995]. 

19 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

To approve respirators with CBRN protection (commonly referred to as CBRN RPDs), NIOSH and its 

federal partners researched hazards, defined appropriate standards for each type of respirator, 

established test procedures, defined product and packaging markings, and determined appropriate 

cautions and limitations of use. Because these CBRN RPD requirements are not prescribed in 42CFR84, 

the standards, tests, applications for approval, and other requirements (e.g., fees) are voluntary, not 

mandatory. All other requirements of 42CFR84 (e.g., Subpart A: General Provisions, Subpart B: 

Application for Approval, Subpart D: Approval and Disapproval, Subpart E: Quality Control, Subpart F: 

Classification of Approved Respirators, and Subpart G: General Construction and Performance) and the 

NIOSH approval program investigative activities described above also apply to NIOSH-approved CBRN 

RPDs and the applicant to whom the certificate of approval is issued. Applicants submitting an 

application for a NIOSH CBRN RPD approval do so with this knowledge. 

NIOSH established additional voluntary requirements for several types of RPDs with CBRN protection— 

including SCBAs (see Figure 2-1)[NIOSH 2001], APRs (gas masks) (see Figure 2-2)[NIOSH 2003b], PAPRs 

(see Figure 2-3)[NIOSH 2006b], and air-purifying escape respirators (APERs) (see Figure 2-4)[NIOSH 

2003a] – to meet the needs of a diverse range of emergency responders (fire fighters, law enforcement, 

and emergency medical services), work activities, durations of use, and hazards. NIOSH continues to 

establish standards and test requirements for other types of respirators, such as those with a 

combination of respirator types. 

Figure 2-1. CBRN SCBA Figure 2-2. CBRN APR 

Figure 2-3. CBRN PAPR Figure 2-4. CBRN APER 

20 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

CBRN Protection – Key Standards and Tests 

To acquire a NIOSH certificate of approval for a respirator with CBRN protection, an applicant must first 

obtain a NIOSH approval for the respirator type meeting the applicable requirements in 42CFR84. The 

applicant must also voluntarily meet additional national or international requirements (e.g., National 

Fire Protection Association, American Society for Testing and Materials, Military, and European 

Standards) and special tests for CBRN protection specified by NIOSH in accordance with §84.60[b], 

§84.63[c], or §84.110[c] as applicable to the respirator type. For information on the details of the 

42CFR84 requirements, refer to Title 42 Code of Federal Regulations Part 84, Respiratory Protective 

Devices; Final Rules and Notice [Approval of respiratory protective devices, 1995]. This Chapter 

describes the key additional requirements for CBRN protection, including: 

1. Chemical Agent Permeation and Penetration Resistance Against Distilled Sulfur Mustard (HD) and 

Sarin (GB)— commonly referred to as “Live Agent Tests” (all CBRN RPD types) 

2. Laboratory Respirator Protection Level (LRPL) Test (all CBRN RPD types) 

3. Canister Gas/Vapor Challenge and Breakthrough Concentration Service Life Tests and Particulate Filter 

Efficiency Tests (APR, PAPR, APER) 

4. National/International Requirements: 

 Durability/environmental conditioning (APR, APER, PAPR (tight-fitting)) 

 Minimum packaging configurations (APR, APER, PAPR (tight-fitting)) 

 Breathing resistance (SCBA, APR, PAPR (tight-fitting), APER) 

 Carbon dioxide and oxygen levels (SCBA, PAPR (loose-fitting), APER) 

 Canister/Cartridge color code (APR, PAPR) 

 Mechanical connector, gasket, tolerance analysis (APR) 

 Field of view, lens material haze, luminous transmittance and lens abrasion resistance (APR) 

 Communications (APR) 

 Fogging (APR, APER) 

 Flammability and heat resistance in accordance with National Fire Protection Association (NFPA) 

Standard 1981 (SCBA, APER with carbon monoxide protection) 

 Training and donning time (APER) 

 Useful life (APER) 

Each of these additional requirements applicable to NIOSH-approved RPDs with CBRN protection is 

briefly described in the following sections. Detailed specifications for the standards and national or 

international requirements are available on the NIOSH, NPPTL website at: 

https://www.cdc.gov/niosh/npptl/stps/respirator_testing.html 

Chemical Agent Permeation and Penetration Resistance Against Distilled Sulfur 

Mustard (HD) and Sarin (GB)–commonly referred to as “Live Agent Tests” (all 

CBRN RPD types) 

NIOSH and its standards development partners (see Chapter 1—Introduction) carefully considered 

comments made by the public during public meetings and comments provided to the NIOSH Docket 002, 

which can be viewed at https://www.cdc.gov/niosh/docket. The emergency response community (e.g., 

International Association of Fire Chiefs, and International Association of Fire Fighters) required that any 

standards and tests for NIOSH-approved CBRN RPDs include performance testing using chemical warfare 

agents (CWAs). 

21 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Anything less was considered unacceptable. Excluding performance testing using CWAs would leave 

responders with a level of uncertainty about the RPD protection, potentially leading to a lack of 

confidence in the protective equipment. 

Based on this input, a systematic evaluation was performed on the physical characteristics of CWAs and 

toxic industrial chemicals (TICs) identified in several sources, including the CWAs listed in the U.S. Army 

Center for Health Promotion and Preventive Medicine (USACHPPM) Technical Guide (TG) 244, the CWAs 

and TICs listed in the NFPA Standard 1994 on Protective Ensembles for Chemical/ Biological Terrorism 

Incidents – 2000 Report on Proposals. A total of 151 CWAs/TICs were identified as potential candidates 

for test agents. As part of the review of their physical properties, the chemicals were evaluated for 

permeation (molecularly diffusing through respirator materials) and penetration (seeping through 

respirator interfacing components). 

Due to their physical properties and molecular structure, Sarin (GB) and Sulfur Mustard (HD) were 

selected as the two representative agents for use during laboratory permeation and penetration tests of 

RPDs. GB is representative of nerve agents, including tabun (GA), soman (GD), and O-ethyl S-[2-

diisopropylamino) ethyl] methylphosphonothioate (VX). Since GB is the most volatile (having a volatility 

of 22,000 mg/m3

) of the nerve agents and evaporates rapidly, it is used in testing only as a vapor agent. 

GB also permeates through materials more readily than G and V nerve agents. HD was selected as a 

representative test agent because of its permeation characteristics. HD is a linear molecule (as compared 

to GB, which has a branched configuration) and is expected to permeate most materials faster than GB. 

A combination liquid droplet and vapor test was defined for HD testing. The test chamber used for 

conducting these tests is shown in Figure 2-5. Figure 2-6 illustrates where liquid droplets of HD are 

placed on the respirator and its components during testing. An HD vapor challenge is introduced into the 

test chamber containing the respirator with liquid HD droplets on it. GB and HD represent challenge 

agents base on given their permeation and penetration characteristics, relative ease to produce, and 

their worldwide availability in thousands of metric tons. 

To determine the applicable level of chemical concentrations of GB and HD for laboratory testing, the 

U.S. Army Research, Development and Engineering Command (RDECOM) developed plausible incident 

scenarios. RDECOM considered possible venues (e.g., small room, large room, arena, and open air areas), 

dissemination devices for release of CWAs, and a wide variation in hazardous vapor concentration-time 

profiles. Scenarios evaluated included worst case (chemical saturation limit), high concentrations, 

Department of Defense military mask concentrations, and U.S. Army Domestic Preparedness evaluation 

levels. RDECOM examined concentration- time profiles by evaluating the cumulative dose for time 

periods associated with various response activities. For example, for first responders wearing SCBAs, a 

period of 30 minutes was used; that time period is based on the capacity of a typical SCBA air cylinder. 

The initial 30 minutes will also generally be the timeframe with the highest concentration as the agent 

dissipates over time. Based on these factors and others (e.g., RPD types) “most credible event 

concentrations” were defined and used as test challenge concentrations during laboratory testing of 

NIOSH-approved RPD against GB vapor, HD liquid droplets, and HD vapor. 

The evaluation also considered concentration level impact on human health to determine an 

appropriate level of protection. Toxicological analysis drawing on test data for GB and HD exposures was 

used to define acceptable limits based on Acute Emergency Guideline Levels (AEGL), established by the 

National Advisory Committee for AEGL for Hazardous Substances. CBRN RPD test criteria for each agent 

were based on a total exposure value (concentration over time), combined with maximum (peak) 

exposure values. 

22 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

The criteria established a cumulative exposure level over a specified period of time for each respirator 

type. The cumulative value was combined with maximum (peak) exposure value that could not be 

exceeded during the test period. Each RPD type has a defined CWA exposure test for specified periods 

based on this analysis and agreed upon by NIOSH and U.S. Army toxicologists. 

Figure 2-5. Live Agent Test Chamber Figure 2-6. SCBA in Live Agent Test Chamber 

Thus, the Chemical Agent Permeation and Penetration Resistance Against Distilled HD and GB Test 

defines the performance of various types of NIOSH-approved respirators with CBRN protection [NIOSH 

2005a,b,c, 2006a]. Based on these laboratory tests specifically defined for each respirator type, the 

following cautions and limitations are placed on the use of the NIOSH-approved CBRN RPDs: 

 CBRN SCBAs should not be used beyond six hours after initial exposure to chemical warfare 

agents (liquid or vapor) to avoid the possibility of agent permeation. 

 CBRN APRs (14G approvala

) should not be used beyond eight hours after initial exposure to 

chemical warfare agents to avoid the possibility of agent permeation or penetration. If liquid 

droplet exposure is encountered, the CBRN APR must not be used for more than two hours. 

 Tight-fitting (14G approval) and loosefitting (23C approvalb

) CBRN PAPRs must not be used 

beyond eight hours after initial exposure to chemical warfare agents to avoid the possibility 

of agent permeation or penetration. If liquid droplet exposure is encountered, the 14G CBRN 

PAPR demonstrated the ability to be used for up to but no more than two hours. The 23C CBRN 

PAPR must not be used where liquid droplet exposure is encountered. 

a NIOSH issues certificates of approval, referred to as a “14G approval,” to APRs, PAPRs, and APERs as tight-fitting full facepiece 

gas mask respirators with canisters. The “14G” refers to the original U.S. Bureau of Mines test schedule (number) and revision 

level (letter) for tight-fitting gas mask respirators with canisters. CBRN APRs, PAPRs, and APERs with a 14G approval must not be 

used in oxygen-deficient atmospheres. These respirators may be used for escape from immediately dangerous to life or health 

(IDLH) atmospheres, but not for entry into them. 

b NIOSH issues certificates of approval, referred to as a “23C approval,” to APRs with cartridges and to PAPRs with loose-fitting 

hoods and helmets with cartridges. The “23C” refers to the original U.S. Bureau of Mines test schedule (number) and revision 

level (letter) for chemical cartridge respirators. CBRN PAPRs with a 23C approval must not be used in oxygen-deficient 

atmospheres. These respirators may not be used for escape from IDLH atmospheres. 

23 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Laboratory Respirator Protection Level (LRPL) Test (all CBRN RPD types) 

The interagency standards development team established several performance and/or design 

requirements applicable to various CBRN RPD types to address a formidable list of potential chemical 

and biological exposures, and accommodate a variety of response activities. The team recognized that 

the substantial level of care and expertise in the design, performance, manufacture, and approvalrelated engineering activities could be undermined if the respirator did not provide an appropriate fit 

between the respirator’s facepiece and the wearer’s face. 

The 42CFR84 standards specified a qualitative fit test to evaluate the ability of RPDs to fit a variety of 

facial sizes. The qualitative tests described in §84.104 [Gas tightness test, 1995] for SCBAs, and §84.124 

[Facepiece tests, 1995] for tight-fitting APRs, including PAPRs, relied on the wearers’ abilities to smell 

isoamyl acetate (i.e., banana oil) and are considered less reliable than modern quantitative fit test 

methodologies. 

The team investigated alternate quantitative fit test methods as a more effective means of measuring 

the respirator facepiece fit to the wearer. NIOSH research comparing various respirator fit test methods 

found that the continuous high-flow deep probe method demonstrated high correlation with an actual 

measurement of exposure in a simulated health care setting (laboratory) [Coffey et al. 1998]. The team 

decided to merge the best characteristics of NIOSH and military respirator protection/face-fit testing in 

defining a new laboratory respirator protection level (LRPL) test. Figure 2-7 displays an LRPL test in 

progress. The test provides important information on the clarity of the manufacturer’s user instructions 

and relies on feedback from human test subjects. Therefore, the LRPL test is a practical performance 

test. The test subjects use the instructions provided with the CBRN RPD to guide them in the proper 

preparation, donning, and wearing of the CBRN RPD. 

Figure 2-7. LRPL Test Chamber 

24 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

This LRPL test assesses the ability of a CBRN RPD facepiece to fit a respirator wearer’s face and does not 

rely on the wearer’s ability to sense a proper fit. It measures the fit and produces a quantitative 

measurement. For each CBRN RPD type, an LRPL value is defined in a laboratory test atmosphere 

containing 20-40 mg/m3 corn oil aerosol of a mass median aerodynamic diameter of 0.4 to 0.6 

micrometers (μm). The test procedure utilizes a quantitative corn oil method to measure the 

concentration of corn oil both outside (in the test chamber) and inside the facepiece when donned on 25 

to 38 human test subjects performing 11 one-minute exercises, including normal breathing, deep 

breathing, moving head side to side, moving head up and down, talking, sighting a mock rifle, reaching 

for the floor and ceiling, looking side to side on hands and knees, making a facial grimace, climbing stairs, 

and repeating normal breathing. The human subjects are selected using the Los Alamos National 

Laboratory recommended anthropometric facial size fit test panel. The exercises include the eight 

exercises (one repeated twice) defined in Occupational Safety and Health Administration (OSHA) 

requirements and three additional exercises–sighting a rifle, climbing stairs, and crawling through low 

spaces. 

The acceptable LRPL value (protection level) and test conditions vary depending on the CBRN RPD type 

[NIOSH 2001,2003a,b, 2006b]. The following represents LRPL test specifications for each CBRN RPD type: 

 SCBA – The measured LRPL for each open-circuit positive pressure SCBA shall be ≥ 500 when the SCBA 

facepiece is tested without the benefit of the air cylinder and the positive pressure inside the mask 

(negative pressure mode) in an atmosphere containing 20-40 mg/m3 corn oil aerosol of a mass median 

aerodynamic diameter of 0.4 to 0.6 μm.

 APR gas mask – The measured LRPL for each APR respirator shall be ≥ 2000 for greater than 95 percent 

of the trials when the APR facepiece is tested in an atmosphere containing 20-40 mg/m3 corn oil 

aerosol of a mass median aerodynamic diameter of 0.4 to 0.6μm.

o Some tests are performed to confirm that the facepiece can be used effectively with a canister 

of the maximum allowable weight of 500 grams size and dimensions permitted by NIOSH 

requirements. This additional modified test for CBRN APRs evaluates the ability of the respirator 

facepiece to properly fit if used in an emergency interoperable configuration with a canister 

from another manufacturer’s NIOSH-approved CBRN APRs. 

 Tight- and loose-fitting PAPR – The LRPL for each PAPR shall be 10,000 for ≥ 95 percent trials with 

the blower operating in an atmosphere containing 20-40 mg/m3 corn oil aerosol of a mass median 

aerodynamic diameter of 0.4-0.6 μm. For tight-fitting PAPRs only, the LRPL shall be ≥ 2,000 for 95 

percent trials with the blower not operating. A modified LRPL using a sample size of eight subjects 

will be used for evaluation. The respirator is tested in an atmosphere containing 20-40 mg/m3 corn 

oil aerosol of a mass median aerodynamic diameter of 0.4-0.6 μm.

 APER – The measured LRPL for each APER shall be ≥ 2000 for 95 percent of trials, sampled in the 

breathing zone of the respirator, and shall be ≥ 150 for 95 percent of trials sampled outside the 

breathing zone (under the hood). The respirator is tested in an atmosphere containing 20-40 mg/m3 

corn oil aerosol of a mass median aerodynamic diameter of 0.4-0.6 μm.

25 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

User instructions provided by the manufacturer are crucial for properly selecting, donning the respirator 

facepiece, and preparing the respirator for use. The respirator manufacturer may provide unique 

instructions for qualifying the respirator for use by an individual wearer. This could include instructions 

for adjusting the facepiece to fit small or large faces, such as inserting an additional sizing component 

into the mask (called an insert). Some manufacturers may have additional components to use during 

storage to retain the shape of the facepiece. 

Some manufacturers of CBRN RPDs also recommend fit factors during fit testing of individual wearers 

much higher than those typically required of industrial respirators of the same RPD type. For example, 

where industrial tight-fitting full facepiece APRs require an individual fit factor of 500 (i.e., 10 times the 

class assigned protection factor of 50), some manufacturers of tight-fitting full facepiece CBRN APRs 

recommend an individual fit factor up to 2,500 for the CBRN APRs to be used for protection against 

CWAs. Failure to follow manufacturers’ user instructions may result in improperly fitting facepieces to 

certain individual respirator wearers. 

Canister Gas/Vapor Challenge and Breakthrough Concentration Service Life Tests and 

Particulate Filter Efficiency Tests (CBRN APR, PAPR, and APER) 

NIOSH chose gases, vapors, and particulates for use in laboratory test evaluations of CBRN RPDs based 

on a comprehensive review of available technical data and consultations with other government 

agencies (Department of Defense, Department of Justice, and Department of Energy). NIOSH also 

analyzed various chemical data lists, including lists from the Environmental Protection Agency (EPA), 

Agency for Toxic Substances and Disease Registry (ATSDR), NFPA 1994 Standard, USACHPPM Technical 

Guide 244, and other military classified sources [DoD 2001]. This review established a total of 151 

TICs/CWAs as candidates for test challenge agents. 

NIOSH also evaluated various lists of chemicals that could be used in a terrorist incident. In an effort to 

reduce the number of laboratory tests required to evaluate CBRN APRs, PAPRs, and APERs, NIOSH and its 

interagency team categorized potential respiratory hazards into chemical families with a test 

representative agent (TRA) identified for each family. In categorizing the potential hazards into 

representative chemical families, NIOSH gathered a panel of respirator testing experts who developed a 

consensus position in the classification of possible respiratory hazards. A list of chemicals along with a list of 

biological agents and radiological agents identified in the original hazard assessment that were considered in 

developing standard requirements were covered in a presentation entitled, “CBRN Canister Requirements” 

delivered at the 2003 NIOSH public meeting (National Institute for Occupational Safety and Health, 2003). In 

categorizing the potential hazards into representative families, NIOSH deliberated the classification of possible 

respiratory hazards. It was determined to relate the classification of the test representative agents to the sorbentsc 

required to remove the challenge chemicals from the breathing zone of the respirator. The identified chemicals 

were classified into 1) Organic Vapors/Hydrocarbons; 2) Acid Gases; 3) Basic Gases; 4) Special Families 

(e.g., formaldehyde that requires special impregnated carbon); and 5) Unknowns (chemicals which 

require further study). Figures 2-8 and 2-9 show the test chamber and instrumentation used to assess 

the service life of air-purifying canisters and cartridges. 

c Vapor- and gas-removing respirators normally remove the contaminant by interaction of its molecules with a 

granular, porous material, commonly called the sorbent. The general method by which the molecules are removed 

is called sorption [NIOSH 1987]. The sorbent used in canisters and cartridges generally consists of activated carbon. 

Other materials, such as synthetic polymers and zeolite, have been tested for filtration, but no other absorbent has 

proven as widely applicable as activated carbon. 

26 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Figure 2-8. NIOSH Service Life Test Chamber 

Figure 2-9. NIOSH Gas Chromatograph 

27 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

The Organic Vapor/Hydrocarbon class is diverse in its ability to be adsorbed and bound in activated 

carbon. The interagency team concluded that a method to determine the relative absorption affinity of 

carbon was required. Physical properties of the chemicals were the means of classification. A number of 

properties were considered, including molecular weight, boiling point, vapor pressure, relative toxicity, 

and polar/non-polar characteristics. The consensus of the team was that vapor pressure was the single 

best indicator of the ability to be adsorbed on activated carbon. A benefit of this approach is that vapor 

pressure data of most compounds is readily available in literature or via laboratory determinations. 

Vapor pressure limits for acceptability were set at the value of carbon tetrachloride (92 mmHg @ 20°C). 

The lower the vapor pressure, the greater the affinity for the organic vapor/hydrocarbon to activated 

carbon; the higher the vapor pressure, the lesser the affinity to activated carbon. 

The standards for gas masks in Europe and the United States (NIOSH) were reviewed. This included 

reviews of military purchasing specifications for ASZM-T carbon for C2A1 military canisters. The key 

findings of the review were: 

 Some of the chemicals used in testing were redundant, since other test chemicals would ensure 

carbon effectiveness against the gases in question (Chlorine, Hydrogen Chloride, Hydrogen Fluoride, 

Arsine, CS and CN Tear Gases). 

 Cyclohexane is commonly used as an organic vapor test representative agent in European and the 

Japanese standards. Meeting the organic vapor test for a canister and cartridge provides protection 

for all organic vapors having vapor pressures less than that of cyclohexane, which includes 

approximately 61 organic chemicals from the TIC/CWA list including GB and HD. 

 The adsorption of acid gases (32 chemicals) is effectively addressed by laboratory testing using 

cyanogen chloride, hydrogen cyanide, hydrogen sulfide, and sulfur dioxide each as a TRA. 

 Ammonia is an effective TRA for the base gases: ammonia; ally amine; 1,2 dimethyl hydrazine; and 

methyl hydrazine. 

 Formaldehyde, phosgene, phosphine, and nitrogen dioxide are considered special case chemicals 

and must be individually used as TRAs in testing. 

 Phosphine is a hydride and must be removed catalytically (copper+2 and silver impregnates on 

carbon). It is individually used as a TRA. 

In summary, the chemical respiratory inhalation hazards can be addressed through testing the identified 

test representative agents listed in the Table 2.1 (CBRN APR Canister Terrorist Threat Protections). 

A NIOSH-approved CBRN APR canister provides protection against a minimum of 139 identified CBRN 

agents, which are classified into the following 7 families: Organic Vapors (61), Acid Gases (32), Base 

Gases (4), Hydrides (4), Nitrogen Oxides (5), Particulates (32) [composed of 3 chemical, 13 biological, 

and 16 radiological and nuclear particulate threats], and Formaldehyde (1). 

The test representative agents (TRA) NIOSH uses for certification testing to represent each agent family 

are listed. 

28 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Table 2-1. CBRN APR Canister Terrorist Threat Protections 

Acid Gas Family (32 agents) 5-TRA chemicals are 

used for NIOSH certification testing to represent the 

Acid Gas Family. 

They are Cyanogen Chloride, Hydrogen 

Cyanide, Hydrogen Sulfide, Phosgene, and 

Sulfur Dioxide. 

Boron tribromide Hydrogen chloride 

Boron trichloride Hydrogen cyanide (AC) 

Boron trifluoride Hydrogen fluoride 

Bromine Hydrogen iodide 

Bromine chloride Hydrogen sulfide 

Bromine trifluoride Phosgene (CG) 

Carbonyl fluoride Phosphorus trichloride 

Chlorine Silicon tetrafluoride 

Chlorine pentafluoride Sulfur dioxide 

Chlorine trifluoride Sulfur trioxide 

Chlorosulfonic acid Sulfuric acid 

Cyanogen chloride (CK) Sulfuryl chloride 

Dichlorosilane Titanium tetrachloride 

Ethyl phosphonous dichloride Tungsten hexafluoride 

Fluorine Bromine pentafluoride 

Hydrogen bromide Hydrogen selenide 

Nitrogen Oxide Family (5 agents) 1 TRA chemical 

(nitrogen dioxide) is used for NIOSH certification 

testing to represent the Nitrogen Oxide Family. 

Nitric acid Nitrogen tetraoxide 

Nitric acid, fuming Nitrogen trioxide 

Nitrogen dioxide 

Base Gas Family (4 agents) 

1 TRA chemical (Ammonia) is used for NIOSH 

Certification testing to represent the Base Gas Family. 

Allyl amine Dimethyl hydrazine, 1,2 

29 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Ammonia Methyl hydrazine 

Hydride Family (4 agents) 

1 TRA chemical (Phosphine) is used for certification 

testing to represent the Hydride Family. 

Arsine Phosphine 

Germane Stibine 

Formaldehyde Family (1 agent) 

1 TRA chemical (Formaldehyde) is used for 

certification testing to represent the Formaldehyde 

Family. 

Formaldehyde 

Organic Vapor Family (61 agents) 

1 TRA chemical (Cyclohexane) is used for certification 

testing to represent the Organic Vapor Family. 

NOTE: Chemical warfare agents are in this TRA 

OV family. 

Acetone cyanohydrin Methanesulfonyl chloride 

Acrylonitrile Methyl orthosilicate 

Allyl alcohol Methyl parathion 

Allyl chlorocarbonate Methyl phosphonic dichloride 

Bromoacetone Mustard, lewisite mixture 

Bromobenzylcyanide (CA) Nitrogen mustard HN-1 

Chloroacetone Nitrogen mustard HN-2 

Chloroacetonitrile Nitrogen mustard HN-3 

Chloroacetophenone (CN) N-propyl chloroformate 

Chloroacetyl chloride O-chlorobenzylidene malononitrile (CS) 

Chloropicrin (PS) O-ethyl-s-(2isopropyaminoethyl)methyl 

phosphonthiolate 

Chloropivaloyl chloride Parathion 

Crotonaldehyde Perchloromethyl mercaptan 

Cyclohexyl methyphosphonate Phenyl mercapatan 

Dibenz-(b,f)-1,4-oxazepine (CR) Phenylcarbylamine chloride 

30 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Diketene Phenyldichloroarsine 

Dimethyl sulfate Phosgene oximedichloroforoxime 

Diphenylchloroarsine Phosphorus oxychloride 

Diphenylcyanoarsine Sarin (GB) 

Diphosgene (DP) Sec-butyl chloroformate 

Distilled mustard (HD) Soman (GD) 

Ethyl chloroformate Tabun (GA) 

Ethyl chlorothioformate Tert-octyl mercapatan 

Ethyl phosphonothioicdichloride Tetraethyl dithiopyrophosphate 

Ethyl phosphorodichloridate Tetraethyl lead 

Ethylene dibromide Tetramethyl lead 

Hexachlorocyclopentadiene Tetranitromethane 

Hexaethyl tetraphosphate Trimethoxysilane 

Iso-butyl chloroformate Trimethylacetyl chloride 

Iso-propyl chloroformate VX 

Lewisite (L, L-1, L-2, L-3) 

Particulate biological agents, particulate radiological/nuclear agents, and other particulates were also 

considered as part of the development of test representative agents. The respiratory hazard posed 

by radiological or nuclear material results primarily from the dispersion of radioisotope dust particulates. 

The respiratory route of exposure to biological agents may be through the dispersion of aerosols or 

droplets. NIOSH-approved P100 filtersd are appropriate for filtration of these particles. Thirteen 

biological hazards including bacteria, viruses, and toxins that could be used as biological weapons are 

addressed as part of the standard. They include Anthrax (bacillus anthracis), Brucellosis (Brucella), 

Glanders (bacterium Burkholderia mallei), Pneumonic Plague (bacterium Yersinia pestis), Tularemia 

(bacterium Francisella tularensis), Q Fever (bacterium Coxiella burnetii), Smallpox (ariola major and 

Variola minor), Venezuelan Equine Encephalitis genus Alphavirus, family Togaviridae), Viral Hemorrhagic 

Fevers (filoviruses, arenaviruses, bunyaviruses, flaviviruses), T-2 Mycotoxins (Trichothecene mycotoxins), 

Botulism (bacterium botulinum), Ricin (Ricinus communis), and Staphylococcus Enterotoxin B 

(Staphylococcus aureus) [NIOSH 2002]. The 16 radiological/nuclear agents addressed as part of the 

standard are Hydrogen 3, Carbon 14, Phosphorous 32, Cobalt 60, Nickel 63, Strontium 90, Technetium 

99m, Iodine 131, Cesium 137, Promethium 147, Thallium 204, Radium226, Thorium 232, Uranium 235 & 

238, Plutonium 239, and Americium 241 [NIOSH 2002]. Three additional chemicals—Adamsite, Sodium 

Azide, and Sodium Fluoroacetate—are addressed as part of the standard through particulate testing 

[NIOSH 2002]. Particulate filter efficiency testing described in 42CFR84, Subpart K was determined to be 

appropriate for filters of a CBRN RPD. 

d 42CFR84, Subpart K [§84.179(3)] defines a P100 filter as one having 99.97 percent efficiency with a label color of 

magenta, indicating it is a high efficiency particulate air (HEPA) filter. 

31 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

In contrast to particulate filters, which are effective no matter what the particulate, cartridges and 

canisters used for vapor and gas removal protect against specific contaminants. To establish a test 

concentration and acceptable breakthrough level (pass/fail criterion) for each TRA, laboratory 

benchmark evaluations of existing NIOSH-approved gas mask canisters were analyzed to generate 

baseline performance data. The gas and vapor removal mechanisms (adsorption, absorption, 

chemisorption, and catalysis) were also considered for various canistersand gas and vapor TRAs.e Where 

a canister uses a catalyst in the sorbent to influence the rate of reaction, there is a potential to create 

daughter byproducts that are toxic. These byproducts could potentially be as toxic as or more toxic than 

the atmospheric contaminant to be filtered. Thus, for the TRA where there is a concern for breakthrough 

of daughter byproducts, both the test agent and daughter products were monitored during testing. 

The test concentration levels for a respirator cartridge were calculated by comparing the higher of a 

safety factor multiplier (varied depending on the TRA) on the NIOSH recommended exposure limit (REL) 

or OSHA permissible exposure limit (PEL), or three times the immediately dangerous to life or health 

(IDLH)f value. In the instances where values other than the higher REL/PEL or IDLH values were used, the 

selection of an alternate value was based on test technology limitations or OSHA advice. Canister test 

concentrations were double the level used for the canister. To establish the test and breakthrough 

concentrations, several iterations of NIOSH benchmark testing of cartridges and canisters were 

conducted. 

Table 2-2 summarizes the standard established for gas life test challenge and breakthrough 

concentrations for canisters used on CBRN APRs and tight-fitting CBRN PAPRs, and cartridges used with 

loose-fitting CBRN PAPRs. NIOSH cartridge and canister gas life tests are performed using a single test 

representative agent challenge concentration. The agents are not combined. 

To determine an appropriate capacity for the CBRN APR canister, NIOSH reviewed national and 

international standards. All standards organizations require that industrial respirators be labeled to 

identify the specific chemical or classes of gases and vapors for which the respirator affords protection. 

The military standards, by contrast, focus on a battery of chemical warfare agent challenges and 

filtration capacity over time. Canister/cartridge gas life is a function of the mass of sorbents, type of 

sorbents utilized, sorbent bed structure, and gas or vapor residence time. 

The European Committee for Standardization (CEN) and Australian standards limit the mass of 

replacement filters to 300 grams for half-mask protection, and 500 grams for full facepiece protection. 

NIOSH and Japanese standards stipulate the minimum gas absorption capacities for each gas or vapor 

without stipulating the mass of the canister and cartridge. 

NIOSH established a standard requiring the applicant, as part of the application for CBRN RPD approval, 

to specify a gas life (i.e., service life under test conditions) period for the canister. Short duration 

capacities are required to be identified in 15-minute intervals (15, 30, and 45). Long duration capacities 

are identified in 30-minute intervals (60, 90, and 120). The canister capacity maximum size limitation is 

based on a maximum canister mass of 500 grams. Figures 2-10 and 2-11 show samples of CBRN 

canisters. In addition, the particulate filter is required to conform to the P100 filter requirements, as 

described in 42CFR84. 

e Cyclohexane was chosen as a TRA because of the health issues associated with using carbon tetrachloride in 

laboratory tests, and the use of Cyclohexane by other standards organizations worldwide. 

f OSHA defines an IDLH value in their hazardous waste operations and emergency response regulation as follows: 

An atmospheric concentration of any toxic, corrosive, or asphyxiant substance that poses an immediate threat to 

life or would cause irreversible or delayed adverse health effects or would interfere with an individual’s ability to 

escape from a dangerous atmosphere (29CFR1910.120). 

32 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Table 2-2. Gas Life Test Challenge and Breakthrough Concentrations for Canisters and Cartridges 

Test Representative Agent Test Concentration (ppm) Breakthrough Concentration (ppm) 

Cartridge Canister 

Ammonia 1250 2500 12.5 

Cyanogen Chloride 150 300 2 

Cyclohexane 1300 2600 10 

Formaldehyde 250 500 1 

Hydrogen Cyanide 470 940 4.7** 

Hydrogen Sulfide 500 1000 5 

Nitrogen Dioxide 100 200 1 ppm NO2, or 25 ppm NO*** 

Phosgene 125 250 1.25 

Phosphine 150 300 0.3 

Sulfur Dioxide 750 1500 5 

* Cartridges and canisters are tested separately against each single TRA 

** Sum of HCN and C2N2 

***Nitrogen Dioxide breakthrough is monitored for both NO2 and NO. The breakthrough is determined by 

which quantity, NO2 or NO, reaches breakthrough first. 

Figure 2-10. CBRN CAP 1 Canister Figure 2-11. CBRN Cap 1 Canister 

33 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

National/International Requirements (CBRN RPD types shown below) 

The key standards and tests described above assure that NIOSH-approved CBRN respirators provide 

protection against chemical warfare agents, toxic industrial chemicals, biological/radiological/ nuclear 

particulates, and other hazardous particulate matter. NIOSH established additional requirements to 

address product durability, environmental conditions, and human interface requirements. These 

additional requirements derive from a variety of national and international standards. The requirements 

vary depending on the RPD type and its intended use. The following is a brief summary of each additional 

requirement. 

Durability/Environmental Conditioning (APR, APER, PAPR (tight-fitting)) 

Before the laboratory evaluations of RPDs submitted to NIOSH for CBRN RPD approval, NIOSH subjects the 

respirator assembly to a number of environmental and rough handling conditions. Table 2-3 below provides a 

synopsis of the rough handling tests. 

Table 2-3. Rough Handling (Transportability, Temperature range, Survivability) 

Test Test Method Test Condition Duration 

Hot Diurnal Mil-Std-810F, 501.4 71 0C max, cyclical 3 Weeks 

Cold Constant Mil-Std-810F, 502.4 Basic Cold, 3 Days 

-32 °C 

Humidity Mil-Std-810E, 507.3 Table 507.3-II, Natural 

Cycle, 

5 Days, 

Quick Look 

Cycle 1 

Vibration Mil-Std-810F, 514.5 US Highway 

Vibration, 

12 Hours / Axis, 

36 Hours Total 

Unrestrained (12,000 miles) 

Figure 514.5C-1 

Drop 3 foot drop Filter Only, 

on to concrete 3 Axis 

N/A 

Note: RPDs are subjected to a hot, cold, humidity, vibration, and drop environmental exposure sequence 

order prior to Service Life High Flow; Service Life, particulate rating and permeation/penetration tests. 

Figures 2-12 and 2-13 show a NIOSH environmental conditioning chamber used to perform these tests. 

Figure 2-12. Outside view of NIOSH Figure 2-13. Inside view of NIOSH 

Environmental Conditioning Chamber Environmental Conditioning Chamber 

34 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Minimum Packaging Configurations 

(APR, APER, PAPR (tight-fitting)) 

NIOSH subjects the CBRN APRs and required components to environmental and durability conditioning 

tests in the manufacturer-specified minimum packaging configuration (MPC). NIOSH also subjects CBRN 

canisters to rough-handling drop tests in their designated MPC. The MPC is the protective packaging in 

which the end user will store or maintain the APR and required components after the APR has been 

issued for use. The end user is the person who will wear the respirator and derive protection from it. 

Failure to store the APR in the manufacturer’s recommended MPC may allow damage to occur and could 

affect the ability to provide the expected level of protection. The damage may not be detectible by the 

user prior to use. 

Examples of common MPCs include hard plastic mask carriers, clamshell containers, drawstring plastic 

bags, cardboard/plastic containers, and hermetically sealed or vacuum-sealed canister bags. Each 

manufacturer is likely to have unique MPC requirements. The manufacturer’s user instructions will 

identify the MPC requirements. 

Breathing Resistance (SCBA, APR, PAPR (tight-fitting), APER) 

Breathing resistance is an important performance characteristic of any CBRN respirator. For each 

respirator type, NIOSH specifies maximum allowable inhalation and exhalation breathing resistances, as 

shown in Table 2-4. The allowable resistances before and after the NIOSH test are described in the 

applicable standard for each respirator type. For example, the resistance to airflow for a CBRN APR is 

measured in the facepiece of the APR mounted on a test fixture with air flowing at a continuous rate of 

85 liters per minute both before and after each gas service life bench test. An example of this test is 

shown in Figure 2-14. The maximum allowable resistance to airflow is as follows: 

Table 2-4. Inhalation and Exhalation Breathing Resistance Requirements 

Chin Style Non Facepiece 

Mounted 

Inhalation: 

Initial 65 mm H2O 70 mm H2O 

Final (1) 80 mm H2O 85 mm H2O 

Exhalation: 20 mm H2O 20 mm H2O 

(1) Measured at end-of-service-life

Figure 2-14. NIOSH Breathing Resistance Measurement 

St 35 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Carbon Dioxide and Oxygen Levels (APR, PAPR (loose-fitting), APER) 

The maximum allowable average inhaled carbon dioxide concentration is less than or equal to one 

percent, measured at the mouth, while the respirator is mounted on a dummy head operated by a 

breathing machine. Figure 2-15 shows the test equipment used to measure carbon dioxide. The 

breathing rate is 14.5 respirations per minute with a minute volume of 10.5 liters. Tests are conducted at 

an ambient temperature of 25 + 5°C. A concentration of five percent carbon dioxide in air is exhaled into 

the facepiece. The minimum allowable oxygen concentration is 19.5 percent. 

Figure 2-15. NIOSH CO2 Test Apparatus 

Canister/Cartridge Color Code (APR, PAPR) 

The canister component/ container label is usually an adhesive label placed on the canister and 

printed label placed on the canister container. It contains less information than a full label. It 

contains the NIOSH emblem; the applicant’s name and address; an approval number assigned by 

NIOSH; and protections, cautions, or limitations of use placed on the RPD by NIOSH. This label does 

not contain the unique configurations of components approved by NIOSH. 

The labels placed on canisters are also color-coded. The color of a CBRN APR canister is olive (Munsell 

notation 7.5 Y 5/6). The color marking can be achieved by either the color of the label or the body of the 

component. Where the color marking is achieved by label color, the body of the component may be any 

color. 

Other individual components of the CBRN APR assembly are not required to contain the NIOSH emblem 

or CBRN marking. However, NIOSH requires that each respirator, respirator component, and container be 

labeled distinctly to show the lot number, serial number, or approximate date of manufacture of the 

component. 

Mechanical Connector, Gasket, Tolerance Analysis (APR) 

To address response community interest in interoperable use of canisters and CBRN RPD facepieces during 

emergencies, NIOSH established design criteria for NIOSH-approved CBRN RPD facepieces and canisters. 

The requirements address the interface between the canister and the respirator facepiece and evaluate it 

as a complete assembly. The respirator assembly is required to use a standard thread in accordance with 

European Standard EN148-1:1999 [European Standards 1999]. 

36 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Thread dimensions are measured with the instrumentation shown in Figure 2-16. The canister is required 

to be readily replaceable without use of special tools. The interface connector on the facepiece is required 

to be the female thread and gasket-sealing gland as identified in EN148-1. The canister shall use a male 

thread in accordance with EN148-1. For respirator assemblies where the filter canister is not directly 

attached to the facepiece, (i.e., not mask mounted) a female thread and gasket sealing gland connector 

complying with EN148-1 must be securely attached to a harness system to provide strain relief between 

the canister and the remaining respirator assembly. In addition to the requirements of EN 148-1, the 

gasket material shall be ethylene propylene diene monomer (EPDM) with a hardness of 65 + 10 shore A 

durometer at room temperature. 

Figure 2-16. NIOSH Optical Thread Comparator 

Field of View, Lens Material Haze, Luminous Transmittance and Lens Abrasion Resistance (APR) 

The full facepiece must have an effective field of vision not less than 70 percent of the natural field of 

vision. The overlapped field of vision must not be less than 20 percent of the natural overlapped field of 

vision. The field of view test procedure is based on procedures of EN136:1998 [European Standards 

1998]. Figure 2-17 shows the instrumentation used for measuring the field of view. 

Specimen CBRN APR facepiece lenses are tested for abrasion resistance. The average value of the tested 

specimens must not exhibit a delta haze greater than 14 percent. The applicant provides test data 

demonstrating compliance with the haze requirement when tested in accordance with NFPA 1981 

Standard on Open-Circuit Self-Contained Breathing Apparatus for Fire and Emergency Services, 2013 

edition, Section 8.9, Facepiece Lens Abrasion Test. Figure 2-18 shows the instrumentation used for 

performing the abrasion resistance and haze measurement. 

37 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Figure 2-17. Stoll Apertometer Test Fixture 

Figure 2-18. Haze Apparatus 

38 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Communications (APR) 

Speech intelligibility testing is accomplished using the Modified Rhyme Test (MRT) [ANSI 1989], which 

evaluates a listener’s ability to comprehend single words, providing an indication of speech transmission 

of the selected words. The MRT consists of multiple lists of 50 monosyllabic, phonetically balanced words 

each. Each individual listener’s average score with the respirator is divided by their average unmasked 

MRT score to calculate a performance rating. The respirator performance rating for communications 

must be greater than or equal to 70 percent when tested in accordance with the communications test 

procedure. 

Fogging (APR, APER) 

The fogging test assesses the visual acuity of human test subjects with and without 

a CBRN RPD that has been laboratory conditioned in an environmental chamber at 15.5°C (60°F), 75 

percent RH for four hours. A test participant enters a test chamber (maintained at -21°C) and sits quietly 

for five minutes. After the five-minute rest period, the participant self- dons the assigned respirator. A 

visual acuity test is then administered to quantify the impact of any lens fogging on vision. Figure 2-20 

shows a fogging test chamber and visual acuity test chart. The respirator performance rating for 

resistance to fogging must be greater than or equal to 70 percent when tested in accordance to the 

fogging test procedure. 

Flammability and Heat Resistance in Accordance with NFPA Standard 1981 

(SCBA, APER with carbon monoxide protection) 

SCBAs are required to meet the standards contained in the applicable edition of NFPA Standard 1981 for 

Open-Circuit Self-Contained Breathing Apparatus for Emergency Services Personnel [NFPA 2013]. 

An APER submitted for NIOSH approval with carbon monoxide protection is required to be tested for 

flammability and heat resistance using the test equipment specified in EN136:1998, Respiratory protective 

devices. Full face masks, requirements, testing, marking, 1998 Edition, Class 1 facepiece. No component of 

the escape respirator assembly is permitted to have an after flame beyond five seconds and no component 

is permitted to drip, melt, or develop a visible hole. 

Figure 2-19. Low Temperature/Fogging Test 

39 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

Training and Donning Time (APER) 

The applicant/manufacturer is required to identify training requirements associated with their APERs. At 

a minimum, this includes an instruction manual that addresses donning procedures, respirator use, 

maintenance (care and useful life), and cautions and limitations. The applicant must provide training aids 

to include a training respirator that mimics the performance of the NIOSH-approved RPD, such as 

inhalation and exhalation breathing resistance that will develop user proficiency in operation of the 

equipment. The applicant must also identify periodic refresher training requirements necessary to 

maintain user proficiency. The training materials are used by NIOSH as the basis for preparing the human 

test subjects in other test procedures such as breathing gas, LRPL testing, and donning. 

The time to don the respirator from the ready-to-use configuration must be no greater than 30 seconds. 

The ready-to-use configuration is the state of the operational packaging prior to use, and means that 

immediately upon opening the packaging, users can don the respirator. 

Useful Life (APER) 

NIOSH defines useful life as the length of time a unit can remain deployed in the manufacturer’s 

specified ready-to-use, stowed condition. NIOSH requires an initial useful life period of no greater than 

five years. However, this period can be extended by the manufacturer through an additional approval 

extension application to NIOSH. The expiration date is provided on packaging and may be located on the 

outside of the storage box and/or on the innermost vacuum-sealed package. 

Hydration (APR) 

For CBRN APRs equipped with a hydration facility (shown in Figure 2-20), the CBRN APR respirator must 

meet all requirements of the CBRN APR standard with the hydration facility in place. In addition, dry 

drinking tube valves, valve seats, or seals are subjected to a suction of 75mm water column height while 

in a normal operating position. Leakage between the valve and the valve seat may not exceed 30 

milliliters per minute. 

Figure 2-20. CBRN APR with Hydration Tube 

40 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

The information provided in this chapter is not a complete description of the standards, tests, and 

additional requirements for NIOSH-approved CBRN RPDs. This chapter provides only a summary of the 

key requirements. For each of the requirements applicable to NIOSH- approved RPD with CBRN 

protection and background information on the standards, visit: 

https://www.cdc.gov/niosh/npptl/respmanuf. For details on the applicable test procedures visit: 

https://www.cdc.gov/niosh/npptl/stps/respirator_testing. 

References 

ANSI [1989]. ANSI S3.2-1989. Diagnostic rhyme test (DRT). Washington, DC: American National 

Standards Institute Inc. 

Approval of respiratory protective devices. 42 CFR 84 (1995). 

Coffey CC, Campbell DL, Myers WR, Zhuang Z [1998]. Comparison of six respirator fit test methods with 

an actual measurement of exposure in a simulated health care environment: part ii – method 

comparison testing. Am. Ind Hyg Assoc. J. 59(12): 862-870. 

DoD [2001]. An overview of the hazards from potential terrorist use of nuclear, biological, and chemical 

(NBC) materials. Classified Report. Washington, DC: US Department of Defense. 

European Standards [1998]. CSN EN 136. Respiratory protective devices. Full face mask. Requirements, 

testing, marking. European Standards 

European Standards [1999]. CSN EN148-1 Respiratory protective devices: threads for facepieces. part 1: 

standard threaded connection. European Standards 

Facepiece tests; minimum requirements. 42 CFR 84.124 (1995). 

Gas tightness test; minimum requirements. 42 CFR 84.104 (1995). 

NFPA [2013]. NFPA 1981 Standard on open-circuit self-contained breathing apparatus for fire and 

emergency services. Quincy, MA: National Fire Protection Association. 

NIOSH [1987]. Guide to industrial respiratory protection. By Bollinger NJ, Schutz RH. Morgantown, WV: 

U.S. Department of Health and Human Services, Centers for Disease Control, National Institute for 

Occupational Safety and Health, DHHS (NIOSH) Publication No. 87-116, 

https://www.cdc.gov/niosh/docs/87-116/pdfs/87-116.pdf. 

NIOSH [2001]. Letter to all interested parties. Acceptance of applications for the testing and evaluation 

of self-contained breathing apparatus for use against chemical, biological, radiological, and nuclear 

agents. By Metzler RW, Acting Director, National Personal Protective Technology Laboratory. December 

28, 2001. Pittsburgh, PA: US Department of Health and Human Services, Centers for Disease Control and 

Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/resources/pressrel/letters/lttr-122801.html. 

41 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

CHAPTER 2 

NIOSH CBRN RESPIRATORY PROTECTIVE DEVICE APPROVAL PROGRAM 

NIOSH [2002]. Concept for CBRN full facepiece air purifying respirator standard. Draft for discussion. 

Pittsburgh, PA: U.S. Department of Health and Human Services, Centers for Disease Control, National 

Institute for Occupational Safety and Health, http://www. cdc.gov/niosh/npptl/standardsdev/cbrn/ 

apr/concepts/pdfs/conceptsep16.pdf 

NIOSH [2003a]. Statement of standard for chemical, biological, radiological, and nuclear (CBRN) airpurifying escape respirator. Pittsburgh, PA: US Department of Health and Human Services, Centers for 

Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/standardsdev/cbrn/escape/standard/pdfs/cbrn-esc-att-a.pdf. 

NIOSH [2003b]. Statement of standard for full facepiece air purifying respirators (APR). Pittsburgh, PA: 

US Department of Health and Human Services, Centers for Disease Control and Prevention, National 

Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/standardsdev/cbrn/apr/standard/aprstd-c.html 

NIOSH [2005a]. Determination of chemical agent permeation and penetration resistance performance 

against sulfur mustard (HD) liquid and vapor of the chemical, biological, radiological, and nuclear (CBRN) 

air-purifying escape respirator standard test procedure (STP). Pittsburgh, PA: US Department of Health 

and Human Services, Centers for Disease Control and Prevention, National Institute for Occupational 

Safety and Health, CET-APRS-STP-CBRN-0451. 

NIOSH [2005b]. Determination of full facepiece, tight-fitting, negative-pressure, air-purifying respirator 

(APR) performance during dynamic testing against chemical agent distilled sulfur mustard (HD) vapor 

and liquid CBRN standard test procedure (STP). Pittsburgh, PA: US Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, RCT-CBRN-APR-STP-0351. 

NIOSH [2005c]. Determination of open circuit, self-contained breathing apparatus (SCBA) performance 

during dynamic testing against chemical agents of sarin (GB) vapor and distilled sulfur mustard (HD) 

vapor and liquid standard test procedure (STP). Pittsburgh, PA: US Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, RCT-CBRN-STP-0200, 0201. 

NIOSH [2006a]. Determination of CBRN, powered air-purifying respirator (PAPR) performance during 

dynamic testing against chemical agent distilled sulfur mustard (HD) vapor and distilled sulfur mustard 

(HD) liquid chemical, biological, radiological, and nuclear (CBRN) standard testing procedure (STP). 

Pittsburgh, PA: US Department of Health and Human Services, Centers for Disease Control and 

Prevention, National Institute for Occupational Safety and Health, NPPTL-STP-CBRN-PAPR-0551. 

NIOSH [2006b]. Statement of standard for chemical, biological, radiological, and nuclear (CBRN) 

powered air-purifying respirators (PAPR). Pittsburgh, PA: US Department of Health and Human Services, 

Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/pdfs/CBRNPAPR/CBRNPAPRStatementofStandard.pdf. 

42 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

CHAPTER 3 – 

CBRN RESPIRATOR EQUIPMENT 

Authors: Osvaldo R. Medici; Richard W. Metzler; Jonathan V. Szalajda; and Timothy R. Rehak 

Introduction 

Chemical, biological, radiological, and nuclear (CBRN) respirators provide respiratory protection against 

warfare and chemical agents that may be present in terrorist attacks or other hazardous material 

emergencies. These are the type of respiratory protection equipment subject to the requirements of 

new standards developed by the National Institute for Occupational Safety and Health (NIOSH) in 

voluntary approval programs pursuant to 42 Code of Federal Regulations (CFR) [Approval of respiratory 

protective devices, 1995]. NIOSH developed CBRN standards (as explained in Chapter 2) for selfcontained breathing apparatus (SCBAs) [NIOSH 2002], air-purifying respirators (APRs) [NIOSH 2003b], 

powered air-purifying respirators (PAPRs) [NIOSH 2006b], and air-purifying escape respirators (APERs) 

[NIOSH 2003a]. 

This chapter describes different types of CBRN respirators and the unique characteristics that distinguish 

them from similar industrial respirators. This information will help users and the authorities with 

jurisdiction to develop written respiratory protection programs that meet the requirements of 

Occupational Safety and Health Administration (OSHA) respiratory protection regulation [OSHA 1999]. 

This information can also be used in training programs for CBRN respirators, as stated in OSHA’s 

Hazardous Waste regulation (HAZWOPER) [OSHA 2006] and National Fire Protection (NFPA) standards 

472 [NFPA 2013b], 473 [NFPA 2013c], and 1404 [NFPA 2013a]. Chapters 5 and 9 describe these 

requirements in more detail. 

There are important performance, design, and use characteristics for CBRN respiratory protective 

devices (RPDs) that a user must understand in order to use these devices effectively. These are: 

 How to recognize that a respirator has CBRN protection 

 The limitations of the equipment and where to find them 

 The shelf and service life of canisters or cartridges 

 Maintenance requirements and schedules 

 How to dispose of CBRN RPDs 

Proper selection and usage of CBRN RPDs should not interfere with other personal protective equipment 

(PPE) ensembles, such as a body protection. The adequate selection of PPE should complement the 

respiratory protection needed for a particular protection level. Responders should select PPE by carefully 

considering the expected type of hazard(s) that may be present at the scene and the potential impact on 

the responder’s life in any given response situation. The NIOSH Publication No. 2008-132, “Guidance on 

Emergency Responders Personal Protective Equipment (PPE) for Response to CBRN Terrorism Incidents,” 

presents information on emergency responder PPE [NIOSH 2008b]. 

43 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

CBRN Respirators’ Unique Features 

The testing procedures used by NIOSH during the approval process relate to the unique features of a 

CBRN RPD. Depending on the type of CBRN RPD, the RPDs must pass tests such as chemical warfare 

agent permeation resistance, laboratory respirator protection level (LRPL), and environmental 

conditioning to gain CBRN approval. The standard testing procedures for each CBRN device can be found 

at the National Personal Protective Technology Laboratory (NPPTL) website [NIOSH 2016]. 

The NIOSH Certified Equipment List identifies approved CBRN respirators [NIOSH 2017]. Approved CBRN 

respirator types include: 

 CBRN Self-Contained Breathing Apparatus (SCBA) 

 CBRN Powered Air-Purifying Respirator (PAPR) 

 CBRN Air-Purifying Respirator (APR) 

 CBRN Air-Purifying Escape Respirator (APER) 

This chapter will focus on these four types of CBRN RPDs. Information will be provided, as appropriate, in 

the following areas: 

 Description 

 Approval labels 

 Testing, cautions, and limitations 

 Canister packaging and shelf life 

 Canister service life 

 Minimum packaging configuration (MPC) 

Components and accessories for CBRN APRs are also discussed. These include CBRN PAPR batteries, 

CBRN PAPR retrofit kits, and CBRN APR accessories. It is important to confirm the components required 

in a NIOSH-approved configuration. Manufacturers may offer additional components that are optional 

accessories. For example, one manufacturer may offer a lens cover (outsert) as an optional component 

to the facepiece, whereas another manufacturer’s RPD may require the lens outsert as a condition of 

approval. 

CBRN Self-Contained Breathing Apparatus 

Description 

The CBRN SCBA was first adopted as an upgrade or option to firefighters’ SCBA, as compliant with the 

performance requirements of NFPA 1981, 2002 Edition [NFPA 2002]. However, NIOSH approved the first 

SCBA CBRN equipment configurations based on NFPA 1981, 1997 Edition [NFPA 1997]. When this 

standard was revised in 2007, the CBRN protection became a mandatory requirement for the NFPA 

1981, 2007 Edition [NFPA 2007], in accordance with the NIOSH Statement of Standard for NIOSH CBRN 

SCBA Testing. Subsequent 2013 Edition of NFPA 1981 also contains CBRN requirements. 

SCBAs that are compliant with the later edition can be used to protect users during structural fires, as 

well as to provide respiratory protection from CBRN agents during a terrorist attack [NFPA 1997]. 

44 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

SCBAs are the only class of CBRN respirator that may be used for both entry into and escape from 

hazardous atmospheres that are immediately dangerous to life or health (IDLH). The Occupational Safety 

and Health Administration (OSHA) Hazardous Waste Operations and Emergency Response regulation 

defines an IDLH atmosphere as an atmospheric concentration of any toxic, corrosive, or asphyxiate 

substance that poses an immediate threat to life or would cause immediate threat to life or would cause 

irreversible or delayed adverse health effects or would interfere with an individual’s ability to escape 

from a dangerous atmosphere [OSHA 2006]. This includes atmospheres that: 

 Contain a contaminant (or contaminants) at concentrations above its listed IDLH concentration 

 Contain an unknown contaminant (or contaminants) or an unknown concentration of known 

contaminant (or contaminants) 

 Contain less than 19.5 percent oxygen 

The specific designs of CBRN SCBAs differ, but all include the same basic components, shown in Figure 3-1: 

Figure 3-1. CBRN SCBA Detachable Regulator Model compliant

 with NFPA 1981 and 1982, Edition 2007. Adapted from 

Mine Safety Appliances. 

 Breathing air cylinder 

 Backframe/harness assembly 

 Regulator 

 Pneumatic lines 

 Facepiece assembly with exhalation valve 

45 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Figure 3-2 shows a CBRN SCBA worn by an emergency responder. 

Figure 3-2. CBRN SCBA equipment used in an emergency 

response in which the contaminants are not known. 

It is important for the user to understand the cautions and limitations of the CBRN SCBA and become 

familiar with all the labels required by NIOSH and NFPA standards to identify the capabilities and 

limitations of the equipment. 

Approval Labels 

NIOSH-approved CBRN SCBAs can be easily recognized by their approval labels. The full NIOSH approval 

label for a CBRN SCBA is shown in Figure 3-3. It is included as a paper insert or part of the CBRN SCBA 

user instructions. This label shows the approved configurations based on their NIOSH TC-XXX approval 

numbers, the approved protection, component part numbers, and the cautions and limitations for each 

approved assembly. 

46 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Example Approval Label for CBRN Self-Contained Breathing Apparatus Respirators 

Double Wing Manufacturing Company 

Almost Heaven, West Virginia, USA 

1-800-123-4567 

1900 Series CBRN SCBA 

Open-Circuit, Pressure-Demand, Entry and Escape CBRN Self-Contained Breathing Apparatus 

These Respirators are Approved Only in the Following Configurations: 

Respirator Components 

TC- Protection 1 Alternate Facepiece Alternate Harness Alternate Cylinder 

Alternate 

Regulator Accessories 

Cautions and 

Limitions2/3 

C 

0 

10 20 30 40 C0 C0 C0 0 R1 R2 R3 Len Alar Cas 

00 00 00 00 H95 H96 H97 H98 H99 01 02 03 4 11 22 33 s10 m50 e20 

30 min/ 

13F- 2216 psi/ 

AARa SC/PD/ IJMNOS, 

-CBRN EOSTI 33 X X X X X X X X X X X ORTUEBSS 

13F- 30 min/ 

AARb 4500 psi/ 

- SC/PD/ IJMNOS, 

CBRN EOSTI 33 X X X X X X X X X X X X ORTUEBSS 

13F- 45 min/ 

AARc 2216 psi/ 

- SC/PD/ IJMNOS, 

CBRN EOSTI 33 X X X X X X X X X X ORTUEBSS 

13F- 60 min/ 

AARd 2216 psi/ 

- SC/PD/ IJMNOS, 

CBRN EOSTI 33 X X X X X X X X X ORTUEBSS 

1. PROTECTION 

PD - Pressure-Demand EOSTI - End-of-Service-Time Indicator 

SC - Self-Contained CBRN – Chemical, Biological, Nuclear and Radiological 

2. CAUTIONS AND LIMITATIONS 

I - Contains electrical parts which have not been evaluated as an ignition source in flammable or explosive atmospheres by MSHA/NIOSH. 

J- Failure to properly use and maintain this product could result in injury or death. 

M- All approved respirators shall be selected, fitted, used, and maintained in accordance with MSHA, OSHA, and other applicable regulations. 

N- Never substitute, modify, add, or omit parts. Use only exact replacement parts in the configuration as specified by the 

manufacturer. 

O - Refer to User Instructions, and/or maintenance manuals for information on use and maintenance of these respirators. 

S - Special or critical User Instructions and/or specific use limitations apply. Refer to User Instructions before donning. 

3. CAUTIONS AND LIMITATIONS OF USE FOR CBRN SCBA 

Q - Use in conjunction with personal protective ensembles that provide appropriate levels of protection against dermal hazards. 

R - Some CBRN agents may not present immediate effects from exposure, but can result in delayed impairment, illness, or death. 

T - Direct contact with CBRN agents requires proper handling of the SCBA after each use and between multiple entries during the same use. 

Decontamination and disposal procedures must be followed. If contaminated with liquid chemical warfare agents, dispose of the SCBA after 

decontamination. 

U - The respirator should not be used beyond 6 hours after initial exposure to chemical warfare agents to avoid possibility of agent permeation. 

EBSS - EBSS Activation or engagement of EBSS in either the donor or receiver mode changes the SCBA use to Escape-Only, approved service 

time for either the donor, or the receiver. 

Figure 3-3. Full NIOSH Label for a CBRN SCBA* (The original form can be accessed 

through the manufacturer of the specific RPD.) 

47 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

In addition to the full label above, two NIOSH sticker labels (abbreviated) are affixed to the 

backframe/harness. Figure 3-4 shows the TC-13F NIOSH adhesive label listing the approval numbers and 

cautions and limitations. Figure 3-5 shows the NIOSH CBRN protection approval and upgrade labels by 

NIOSH or the CBRN retrofit sticker label when the equipment has been upgraded for CBRN protection. 

Example Approval Label for Self-Contained Breathing Apparatus Harness 

Double Wing Manufacturing Company 

Almost Heaven, West Virginia, USA 

1-800-123-4567 

Model FFCBRN SCBA 

Open-Circuit, Pressure-Demand, Entry and Escape Self-Contained Breathing Apparatus 

TC-13F-XXXCBRN 30 MINUTE 2216 PSIG 

TC-13F-YYYCBRN 30 MINUTE 4500 PSIG 

TC-13F-ZZZCBRN 45 MINUTE 4500 PSIG 

TC-13F-AAACBRN 60 MINUTE 4500 PSIG 

(Refer to the Approved User Instructions for the Complete List 

of Components that Make Up the Approved Assembly) 

Cautions and Limitations 

I - Contains electrical parts which have not been evaluated as an ignition source in flammable or explosive 

atmospheres by MSHA/NIOSH. 

J - Failure to properly use and maintain this product could result in injury or death. 

M - All approved respirators shall be selected, fitted, used, and maintained in accordance with MSHA, OSHA, and 

other applicable regulations. 

N - Never substitute, modify, add, or omit parts. Use only exact replacement parts in the configuration as specified 

by the manufacturer. 

O - Refer to User Instructions, and/or maintenance manuals for information on use and maintenance of these respirators. 

S - Special or critical User Instructions and/or specific use limitations apply. Refer to User Instructions before 

donning. 

Q - Use in conjunction with personal protective ensembles that provide appropriate levels of protection against 

dermal hazard. 

R - Some CBRN agents may not present immediate effects from exposure, but can result in delayed impairment, 

illness, or death. 

T - Direct contact with CBRN agents requires proper handling of the respirator after each use and between multiple 

entries during the same use. Decontamination and disposal procedures must be followed. If contaminated 

with liquid chemical warfare agents, dispose of the respirator after decontamination. 

U - The respirator should not be used beyond 6 hours after initial exposure to chemical warfare agents to avoid 

possibility of agent permeation. 

Figure 3-4. NIOSH 13F Approval Harness Label 

48 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

One or more sticker labels affixed to the backframe/harness show compliance with NFPA 1981. This label 

bears the logo of the Safety Equipment Institute (SEI), a third party organization that administers the 

NFPA certification program for SCBAs. This label is shown in Figure 3-6. 

Figure 3-5. NIOSH “CBRN Agent Approved” Label (adhesive) for new and retrofitted CBRN SCBA 

THIS SCBA MEETS THE REQUIREMENTS OF NFPA 1981, 

STANDARD ON OPEN-CIRCUIT SELF-CONTAINED 

BREATHING APPARATUS (SCBA) FOR EMERGENCY 

SERVICES, 2013 EDITION. 

CERTIFIED MODEL 

DO NOT REMOVE THIS LABEL 

Figure 3-6. Example of the NFPA Compliance Label Issued by SEI 

49 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

It is important to check all these approval labels to be sure that the SCBA is CBRN approved by NIOSH. If 

these labels do not show the CBRN designation, the respirator is not approved to provide protection 

against CBRN agents. 

Facepieces, regulators, valves, hoses, and cylinder connections are the main components that may differ 

in materials or construction from non-CBRN SCBAs. Thus, only those components with exact part 

numbers shown on the full NIOSH CBRN SCBA approval label provide CBRN protection and maintain 

NIOSH approval. 

It is important to emphasize the unique features of CBRN SCBAs that set them apart from their industrial 

counterparts. These are explained in detail in the CBRN SCBA standards and test procedures, which are 

posted on the NIOSH NPPTL website [NIOSH 2016]. 

Testing 

Chemical Agent Permeation and Penetration Resistance Tests 

Chemical agent permeation and penetration tests ensure that under specified laboratory conditions, the 

materials used in the CBRN SCBAs resist chemical warfare agent (CWA) migration into the respirator 

assembly according to NIOSH Standard Test Procedure RCT-CBRN-STP-0200 and 0201, covered in Chapter 2. 

Laboratory Respirator Protection Level (LRPL) 

The fit of each NIOSH-approved CBRN SCBA facepiece is evaluated to ensure a minimum LRPL under 

specified laboratory conditions. This test assesses the respirator’s ability to fit a wide range of facial sizes 

and shapes. It also ensures that user instructions can be understood. Chapter 2 provides details on the 

LRPL test procedures found in the NIOSH Standard Test Procedure document TEB-CBRN-APR- STP0352 

[NIOSH 2008a]. 

LRPL testing ensures CBRN SCBAs have generally good fitting characteristics for a variety of facial sizes 

and shapes. However, individual fit testing must be done to select the correct facepiece model and size 

for each individual wearer. Quantitative fit tests are acceptable to OSHA for CBRN SCBAs. The user 

instructions must be consulted for additional details on fit testing in order to properly select the 

equipment and to perform the recommended fit testing protocol. 

NIOSH Cautions and Limitation Statements 

NIOSH requires specific cautions and limitations (C&L) statements for 42CFR84 13F SCBAs, and additional 

specific statements for CBRN SCBAs. Each C&L statement is identified by a letter code [NIOSH 2006a]. 

These codes and statements, shown in Table 3-1, are the same for all manufacturers that produce 

NIOSH-approved SCBAs. In practice, the wording of the statements may vary slightly among SCBA 

manufacturers, and additional C&L statements may be added by the manufacturer for a specific product. 

Therefore, the user instructions must be consulted to gain a complete understanding of the C&L for that 

particular respirator device. 

50 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

I Contains electrical parts that may cause an ignition in flammable or explosive atmospheres. 

J 

M All approved respirators shall be selected, fitted, used, and maintained in accordance with MSHA, 

OSHA, and other applicable regulations. 

N 

O Refer to user instructions and/or maintenance manuals for information on use and maintenance 

of these respirators. 

S 

Q* Use in conjunction with personal protective ensembles that provide appropriate levels of 

protection against (CBRN agent) dermal hazards. 

R* 

T* Direct contact with CBRN agents requires proper handling of the SCBA after each use and 

between multiple entries during the same use. 

U* 

EBSS* 

Failure to properly use and maintain this product could result in injury or death. 

Never substitute, modify, add, or omit parts. Use only exact replacement parts in the 

configuration specified by the manufacturer. 

Special or critical user instructions and/or specific use limitations apply. Refer to user instructions 

before donning, due to unique or unusual design or critical operation requirements. 

Some CBRN agents may not present immediate effects from exposure, but can result in delayed

impairment, illness, or death. 

The respirator should not be used beyond 6 (six) hours after initial exposure to chemical 

warfare agents to avoid possibility of continued agent permeation.” 

Activation or engagement of EBSS in either the donor or receiver mode changes the SCBA use 

to Escape-Only, approved service time for either the donor, or the receiver is no longer 

applicable. Additional critical cautions and limitations apply. Refer to EBSS in the User's Manual. 

Table 3-1. C&L Statements for CBRN SCBAs 

*CBRN-specific C&L. 

CBRN Powered Air-Purifying Respirators 

Description 

The CBRN PAPR has a blower to provide purified air to the user by drawing the contaminated air through 

an air-purifying canister(s) or cartridges. Important design differences separate CBRN PAPRs from their 

industrial counterparts. 

PAPR Approval Labels 

NIOSH approves CBRN PAPR in two categories: tight-fitting (NIOSH 14G approval) or loose-fitting (NIOSH 

23C approval). Tight-fitting coverings are called facepieces, such as full face masks. They cover the user’s 

face and eyes and form a seal with the face. The loose-fitting coverings cover at least the head and neck 

or the head, neck, and chest. They are called hoods if they are made of a flexible material such as 

rubber, or helmets if they include a rigid protective headgear [NIOSH 1987]. 

CBRN PAPRs with NIOSH 14G approvals may be 

used for escape from IDLH atmoshperes that 

contain at least 19.5 percent oxygen. PAPRs 

with 23C approvals may not be used for escape 

from IDLH atmospheres. Neither class of CBRN 

PAPR can be used to enter an atmosphere that 

is IDLH. 

51 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

During NIOSH laboratory evaluation, the same test agents are used to evaluate PAPR canisters (14G) and 

cartridges (23C). The concentrations are reduced by one-half for loose-fitting PAPR with cartridges. 

NIOSH subjects CBRN PAPRs to special testing to gain CBRN approval. These tests include: 

 Chemical agent permeation and penetration resistance against distilled sulfur mustard (HD) and 

sarin (GB) 

 LRPL 

 Canister/cartridges test challenge and test breakthrough concentrations for the 10 test 

representative agents described in Chapter 2 

 Durability conditioning for CBRN tight-fitting PAPRs only 

When the types of inhalation hazards are known, their concentrations do not exceed IDLH levels, and 

there is at least 19.5 percent oxygen, these CBRN PAPRs may be used to enter contaminated 

atmospheres. 

NIOSH-approved CBRN PAPRs can be recognized by their labels. Two types of NIOSH approval labels 

provide information on the PAPR protections and list of required component configurations: 1) the full 

NIOSH approval label for the CBRN respirator, and 2) the full NIOSH approval label for the CBRN canister 

and cartridge. These are paper labels included with the facepiece and air-purifying component packaging 

and/or provided with the user instructions. Both full labels contain the following information: 

 Department of Health and Human Services and National Institute for Occupational Safety and 

Health logos 

 Respirator components, protections, accessories, and cautions and limitations 

 Part numbers of components for each NIOSH-approved CBRN APR or canister 

configuration/systemThe NIOSH approval number (TC-14G-XXX or TC-23C-XXX), shown as a row 

of component parts—each row represents required components for a specific approved 

configuration 

 Type and level of protection—the configuration(s)of componentsthat are approved for CBRN 

level of protection listed with “CBRN” and a capacity level (i.e., CAP1, CAP2, etc.) 

 Specified cautions and limitations 

There is also an abbreviated adhesive NIOSH approval label on CBRN PAPR canisters and cartridges. This 

label does not contain the approved configuration of components. In addition, the information of this 

label may be split between the CBRN canister/cartridge component and its packaging. 

The full NIOSH approval label is the most important document to define the correct configuration of the 

CBRN PAPR. As stated before, the full NIOSH approval label may be in the user instructions or as an insert 

paper sheet. The full respirator approval label is usually provided with the PAPR blower unit and/or 

facepiece packaging. 

The full NIOSH approval labels (respirator, canister, and cartridge) should be reviewed to check that the 

components of the CBRN PAPR meet the NIOSH-approved CBRN configuration suitable for the 

application for which it was selected. 

52 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

The NIOSH approval number shows the unique protections for each configuration of the CBRN PAPR. The 

components are marked in the matrix grid. Any components that are not marked in the grid for a given 

approval number are not permitted. 

CBRN PAPR canisters or cartridges must have a NIOSH approval label with a “CBRN” designation. The 

color of the canister or cartridge label will be olive and contain all the information of the full label except 

for the component configurations, as shown in Figure 3-7. 

Canister/cartridge packaging is also labeled “CBRN.” Blower units, breathing tubes, and facepieces do 

not have markings or adhesive labels indicating that they are CBRN components. They are marked with 

a component number, which is listed on the full label identifying that component in the NIOSH-approved 

configuration. 

Testing 

NIOSH tests CBRN canisters or cartridges for PAPRs against 10 test agents representing over 131 

chemicals: ammonia, cyanogen chloride, cyclohexane (organic vapors), formaldehyde, hydrogen 

cyanide, hydrogen sulfide, nitrogen dioxide, phosgene, phosphine, and sulfur dioxide. They are also 

tested against GB, HD, and dioctyl phthalate (DOP) for P100 particulate filtration efficiency. 

These tests evaluate the capacity (CAP) of the canisters, as specified by their manufacturer. They are 

evaluated in 15-minute intervals up to 60 minutes. NIOSH assigns numerical ratings to indicate the 

duration of the tests for which the canister prevented unacceptable chemical breakthrough: CAP1 = 

15 minutes, CAP2 = 30 minutes, and CAP3 = 45 minutes. For CAP ratings of 60 minutes or greater, 

the canisters are evaluated at 30-minute intervals up to 120 minutes. Actual service life in use will 

be affected by the specific chemical exposure, airflow rate, and environmental conditions. 

Figure 3-7. CBRN Canisters Showing the Adhesive NIOSH Approval Label 

53 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

All NIOSH-approved CBRN PAPRs are evaluated to ensure a minimum LRPL and clarity of user 

instructions. The loose- fitting 23C PAPRs are tested with their blower running, under specified 

laboratory conditions. Tight-fitting 14G PAPRs are tested with the blower running and with 

it turned off. NIOSH also assesses the respirator’s ability to fit a wide range of facial sizes and shapes. 

They also ensure that instructions for the facepiece size selection and donning can be understood. 

Although LRPL testing ensures CBRN PAPRs have generally good fitting characteristics, individual fit 

testing must be done to select the correct tight- fitting facepiece model and size for each user. Fit testing 

is not required for loose-fitting PAPRs. Procedures for conducting qualitative and quantitative fit tests 

can be found in OSHA’s Respiratory Protection regulation [OSHA 1999] and Chapter 6 of this handbook. 

Qualitative fit tests rely on the user’s senses to detect unacceptable leakage of a test agent. Quantitative 

fit tests are similar to the LRPL test, using instrumentation to measure “fit factors,” which are numerical 

expressions of fit. 

A minimum fit factor of 500 is required to 

demonstrate acceptable fit. Higher values 

represent “better” fit. While the minimum 

fit factor of 500 satisfies OSHA’s regulation, 

manufacturers of CBRN PAPRs may specify 

higher minimum values (up to 2500) for 

their products. The user instructions must be 

consulted to determine the minimum 

acceptable fit factor for a specific CBRN PAPR. 

NIOSH Cautions and Limitations Statements 

NIOSH requires a standardized list of C&L for each respirator class. The table below shows C&L 

statements for tight-fitting and loose-fitting CBRN PAPRs. Individual manufacturers often have additional 

C&L statements unique to specific respirator models. These are provided in the manufacturer’s user 

instructions. At a minimum, NIOSH requires the C&L statements shown in Tables 3-2 and 3-3 for 

CBRN PAPRs [NIOSH 2006a]. 

54 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Table 3-2. NIOSH C&L Statements for Tight-Fitting CBRN PAPRs 

(14G Approval Schedule) 

A Not for use in atmospheres containing less than 19.5 percent oxygen. 

F Do not use powered air-purifying respirators if airflow is less than four (4) cfm (115 lpm) for 

tight fitting facepieces or six (6) cfm (170 lpm) for hoods and/or helmets. 

H Follow established cartridge and canister change schedules or observe ESLI to ensure that 

cartridges and canisters are replaced before breakthrough occurs. 

I Contains electrical parts that may cause an ignition in flammable or explosive atmospheres. 

(Note - Applies if the respirator contains electrical components and the intrinsic safety has not 

been evaluated and approved by MSHA or a recognized independent laboratory. 

J Failure to properly use and maintain this product could result in injury or death. 

L Follow the manufacturer’s user instructions for changing cartridges, canister, and/or filters. 

M All approved respirators shall be selected, fitted, used, and maintained in accordance with 

MSHA, OSHA, and other applicable regulations. 

N Never substitute, modify, add, or omit parts. Use only exact replacement parts in the 

configuration as specified by the manufacturer. 

O Refer to user instructions, and/or maintenance manuals for information on use and 

maintenance of these respirators. 

R* Some CBRN agents may not present immediate effects from exposure, but can result in delayed 

impairment, illness, or death. 

S Special or critical user instructions and/or specific use limitations apply. Refer to user 

instructions before donning, due to unique or unusual design or critical operation 

requirements. 

Y* The respirator provides respiratory protection against inhalation of radiological and nuclear dust 

particles. Procedures for monitoring radiation exposure and full radiation protection must be 

followed. 

Z* If during use, an unexpected hazard is encountered such as a secondary CBRN device, pockets 

of entrapped hazard or any unforeseen hazard, immediately leave the area for clean air. 

BB Not for use for entry into atmospheres immediately dangerous to life or health. 

CC For entry, do not exceed maximum use concentrations established by regulatory standards. 

GG* Direct contact with CBRN agents requires proper handling of the respirator after use. Correct 

disposal procedures must be followed. 

UU* The respirator should not be used beyond eight (8) hours after initial exposure to chemical 

warfare agents to avoid possibility of agent permeation. If liquid exposure is encountered, the 

respirator should not be used for more than two (2) hours. 

VV* PAPRS with TC-23C approvals may NOT be used for escape from IDLH atmospheres. 

* CBRN-specific C&L. 

55 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Table 3-3. NIOSH C&L Statements for Loose-Fitting CBRN PAPRs 

(23C Approval Schedule) 

A Not for use in atmospheres containing less than 19.5 percent oxygen. 

B Not for use in atmospheres immediately dangerous to life or health. 

C Do not exceed maximum use concentrations established by regulatory standards. 

F Do not use powered air. 

H Follow established cartridge and canister change schedules or observe ESLI to ensure that 

cartridges and canisters are replaced before breakthrough occurs. 

I Contains electrical parts that may cause an ignition in flammable or explosive atmospheres. 

(Note: Applies if the respirator contains electrical components and the intrinsic safety has not 

been evaluated and approved by MSHA or a recognized independent laboratory.) 

J Failure to properly use and maintain this product could result in injury or death. 

L Follow the manufacturer’s user instructions for changing cartridges, canister, and/or filters. 

M All approved respirators shall be selected, fitted, used, and maintained in accordance with 

MSHA, OSHA, and other applicable regulations. 

N Never substitute, modify, add, or omit parts. Use only exact replacement parts in the 

configuration as specified by the manufacturer. 

O Refer to user instructions, and/or maintenance manuals for information on use and 

maintenance of these respirators. 

R* Some CBRN agents may not present immediate effects from exposure, but can result in delayed 

impairment, illness, or death. 

S Special or critical user instructions and/or specific use limitations apply. Refer to user 

instructions before donning, due to unique or unusual design or critical operation 

requirements. 

Y* The respirator provides respiratory protection against inhalation of radiological and nuclear dust 

particles. Procedures for monitoring radiation exposure and full radiation protection must be 

followed. 

GG* Direct contact with CBRN agents requires proper handling of the respirator after use. Correct 

disposal procedures must be followed. 

QQ* Use in conjunction with personal protective ensembles that provide appropriate levels of 

protection against dermal hazard. Failure to do so may result in personal injury even when the 

respirator is properly fitted, used, and maintained. 

UU* The respirator should not be used beyond eight (8) hours after initial exposure to chemical 

warfare agents to avoid possibility of agent permeation. If liquid exposure is encountered, the 

respirator should not be used for more than two (2) hours. 

VV* PAPRS with TC-23C approvals may NOT be used for escape from IDLH atmospheres. 

*CBRN-specific C&L. 

56 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Canister/Cartridge Packaging and Shelf Life 

Packaging for CBRN PAPR canisters and cartridges carry a CBRN designation. The box and the sealed 

wrapping for the canister or cartridge are commonly marked with a shelf life date, which is the time 

period that the canister or cartridge can be used if it has been maintained as specified by its 

manufacturer. Figure 3-8 shows the expiration date of a canister or cartridge. The shelf life varies among 

manufacturers. The time period for a specific canister or cartridge should also be found in the user 

instructions. Canisters and cartridges should be removed from possible service if their expiration period 

has passed. 

Canisters should be stored as specified by their manufacturer, and remain sealed until fitted to the 

respirator just prior to use. Canisters that have had the vacuum seal broken or are otherwise damaged 

should be removed from possible service. 

In-Use Service Life of CBRN Canisters 

When put into use, the service life of canisters depends on the rate of airflow; specific type, volatility, 

and concentration of the contaminants; and environmental conditions, such as humidity and 

temperature. 

Canisters must be replaced in accordance with an established change schedule or P100 filter time-use 

restriction as may be required by manufacturer’s instructions [NIOSH 1997]. Canisters should also be 

replaced immediately if smell, taste, or irritation from contaminants is detected; if they are damaged; or 

if there is a noticeable decrease in PAPR airflow. Chapter 4 of this handbook explains service life 

estimation and establishing change schedules. 

Figure 3-8. CBRN Canister Shelf Life Label 

Minimum Packaging Configuration (MPC) 

The CBRN tight-fitting PAPR and its required components are subjected to environmental and durability 

conditioning in the manufacturer-specified MPC. Canisters are also subjected to a rough handling drop 

test in a designated MPC. This test is not done for loose-fitting NIOSH-approved CBRN PAPR and 

cartridges. 

The MPC is the protective packaging configuration in which the end user will store or maintain the CBRN 

PAPR and its required components after it has been issued for immediate use. The type of MPC, if any, is 

left to the discretion of the manufacturer. 

57 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Examples of common MPCs are mask carriers, clamshell containers, drawstring plastic bags, hermetically 

sealed canister bags, and cardboard containers, as shown in Figure 3-9. 

Figure 3-9. Minimum Packaging Configuration for CBRN Canister and CBRN PAPR System 

CBRN Air-Purifying Respirators 

Description 

CBRN APR RPDs consist of a full facepiece made of materials resistant to permeation of chemical agents 

and a canister to remove hazardous chemicals and particulates [NIOSH 2003b]. Only canisters are 

approved with CBRN APRs; cartridges are not used. Canisters can be mounted on the front or on either 

side of the facepiece. Figures 3-10 and 3-11 show typical CBRN APRs. 

APR Approval Labels 

NIOSH approves these respirators under Schedule 14G (Gas Masks). When the inhalation hazards are 

known and their concentrations do not exceed IDLH levels, and sufficient oxygen (greater than 19.5 

percent) is present, CBRN APRs may be used. They may also be used for escape from IDLH atmospheres 

when adequate oxygen is present. 

. 

Figure 3-10. CBRN APR Protection Figure 3-11. CBRN APR Protection 

for Police Responders for Emergency Responders 

Courtesy Avon Protection Systems Courtesy MSA – The Safety Company 

58 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Testing 

NIOSH subjects CBRN APRs to a range of tests based on existing national and international standards. 

These tests include mechanical connector and gasket properties; canister properties, including breathing 

resistance; dimensions and weight; facepiece field of view; lens material haze, luminous transmittance, 

and abrasion resistance; carbon dioxide level; and hydration. 

Special test requirements for CBRN use include canister challenge and breakthrough concentrations; 

service life; low temperature/fogging (visual acuity score); communications modified rhyme; chemical 

agent permeation and penetration resistance against distilled HD and GB agent; LRPL; and 

environmental conditioning (transportability, temperature range, survivability). 

The 14G approval for CBRN APR is shown in the full NIOSH approval label for the facepiece and canister, 

found with the manufacturer’s user instructions or as an insert in the MPC. The user instructions and the 

full NIOSH respirator approval label are distributed with the facepiece, and the full NIOSH canister 

approval label is distributed with the canister. 

Most CBRN APR components, including facepieces, are not marked “CBRN.” NIOSH only requires the 

canister to be labeled and marked “CBRN,” and requires the color of the canister or its label to be olive. 

NIOSH-approved CBRN APR canisters must provide protection at the same level as the canister specified 

on the NIOSH CBRN approval label. For a service life less than 60 minutes, the canister capacity is 

specified in 15-minute intervals, identified by a capacity level. A capacity level of CAP1 designates a 

laboratory-rated service life of 15 minutes; CAP2 is 30 minutes; and CAP3 is 45 minutes. 

The canister must meet or exceed the manufacturer’s specified service life during the laboratory test 

without exceeding the NIOSH-identified breakthrough concentration level for the test gas or vapor. 

CBRN APR canisters are unique in that they are interoperable among manufacturers. This 

interoperability provision does not apply to NIOSH-approved industrial gas masks. Users should not 

interchange canisters until they are instructed to do so by the incident commander or other 

designated command authority. 

The interoperability requirement for CBRN canisters is intended to ensure that canisters from different 

manufacturers’ NIOSH-approved CBRN APR will provide the same protection level as the canister 

specified on the NIOSH CBRN approval label. The RD-40-1/7” thread used for the canister connectors, 

shown in Figure 3-12, is the round standard thread defined by the European Standard EN148-1:1999 [BSI 

1999]. 

Figure 3-12. CBRN Canisters Showing the Threaded Connection and Abbreviated Adhesive Label 

59 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

NIOSH evaluates the fit of each NIOSH- approved CBRN APR to ensure a minimum LRPL under 

laboratory-specified conditions as described for CBRN PAPRs with tight- fitting facepieces. Figure 3-13 

shows the LRPL testing for APRs. Manufacturers may require fit factors higher than 500 to qualify users 

when individual fit testing is conducted. 

Since different fit factors are required by manufacturers for CBRN APRs (ranging from 500 to 2500), the 

user instructions for the particular device must be consulted. 

NIOSH Cautions and Limitations Statements 

At a minimum, NIOSH requires the C&L statements shown on Table 3-4 for CBRN APRs [NIOSH 2006a]. 

Figure 3-13. CBRN Respirator LRPL Testing 

60 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Table 3-4. NIOSH C&L Statements for CBRN APRs (Approval Schedule 14G) 

A Not for use in atmospheres containing less than 19.5 percent oxygen. 

I Contains electrical parts that may cause an ignition in flammable or explosive atmospheres. 

Applies if the respirator contains electrical components and the intrinsic safety has not been 

evaluated and approved by Mine & Safety Administration (MSHA) or a recognized independent 

laboratory. 

J Failure to properly use and maintain this product could result in injury or death. 

L Follow the manufacturer’s instructions for changing cartridges, canister, and/or filters. 

M All approved respirators shall be selected, fitted, used, and maintained in accordance with 

MSHA, OSHA, and other applicable regulations. 

O Refer to user instructions and/or maintenance manuals for information on use and maintenance 

of these respirators. 

R* Some CBRN agents may not present immediate effects from exposure, but can result in delayed 

impairment, illness, or death. 

S Special or critical user instructions and/or specific use limitations apply. Refer to user 

instructions before donning, due to unique or unusual design or critical operation requirements. 

T* Direct contact with CBRN agents requires proper handling of the respirator after each use and 

between multiple entries during the same use. Decontamination and disposal procedures must 

be followed. If contaminated with liquid chemical warfare agents, dispose of the respirator after 

decontamination. 

V* Not for use in atmospheres IDLH, or where hazards have not been fully characterized. 

W* Use replacement parts in the configuration as specified by applicable regulations and guidance. 

X* Consult manufacturer’s user instructions for information on the use, storage, and maintenance 

of these respirators at various temperatures. 

Y* The respirator provides respiratory protection against inhalation of radiological and nuclear dust 

particles. Procedures for monitoring radiation exposure and full radiation protection must be 

followed. 

Z* If during use, an unexpected hazard is encountered such as a secondary CBRN device, pockets of 

entrapped or any unforeseen hazard, immediately leave the area for clean air. 

CC For entry, do not exceed maximum use concentrations established by regulatory standards. 

HH* When used at defined occupational exposure limits, the rated service time cannot be exceeded. 

Follow established canister change out schedules, or observe End-of-Service-Life Indicators to 

ensure that canisters are replaced before breakthrough occurs. 

QQ* Use in conjunction with personal protective ensembles that provide appropriate levels of 

protection against dermal hazard. Failure to do so may result in personal injury even when the 

respirator is properly fitted, used, and maintained. 

UU* The respirator should not be used beyond eight (8) hours after initial exposure to chemical 

warfare agents to avoid possibility of agent permeation. If liquid exposure is encountered, the 

respirator should not be used for more than two (2) hours. 

*CBRN-specific C&L. 

61 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Canister/Cartridge Packaging and Shelf Life 

Packaging boxes for CBRN canisters carry a CBRN designation, as shown in Figure 3-14. The canister box 

and the canister sealed wrapping are commonly marked with a shelf life date, as explained for CBRN 

PAPRs. 

Figure 3-14. CBRN Canister Shelf Life Label 

In-Use Service Life of CBRN APRs 

Because of the limitations of the permeation and penetration testing, CBRN APRs must not be used 

beyond eight hours after initial exposure to CWA(s) to avoid the possibility of agent permeation. If liquid 

exposure is encountered, the respirator must not be used for more than two hours. 

Minimum Packaging Configuration 

Similar test procedures are used for CBRN APRs as those used for CBRN PAPRs, which are explained 

above. Figures 3-15 and 3-16 show examples of MPCs. 

CBRN Air-Purifying Escape Respirators 

Description 

CBRN APERs consist of a hood made of materials resistant to permeation of chemical agents and a 

canister with media to remove hazardous chemicals and particulates. They typically include an oral/nasal 

cup or mouthpiece to further protect the respiratory system. NIOSH approves these devices as 14G gas 

masks. These devices may be used for escape from IDLH environments, but not for entry into or working 

in an IDLH atmosphere. 

These RPDs are designed for the general working population and provide escape protection against 

CBRN agents. 

62 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Figure 3-15. CBRN Canister MPC Figure 3-16. CBRN Facepiece MPC 

Figure 3-17. CBRN APER Escape Respirators 

Figures 3-17 and 3-18 show examples of CBRN APERs. 

Manufacturers’ user instructions may contain special requirements for the type or frequency of training 

necessary for a given APER. Periodic retraining and/or review of instructions for donning, fitting, and 

doffing must be performed as required by the manufacturer. For example, some manufacturers may 

require retraining every 30 days, while others may require periodic review of instructions or inspection, 

or stipulate inspection requirements without specifying a time interval. 

The NIOSH standard does not address special populations, such as children and adults with respiratory or 

other health conditions that may adversely affect the ability to don and use CBRN APERs effectively. The 

useful life of the APER in the ready-to-use, stowed condition must be specified by the manufacturer. 

CBRN APER canisters are designed to remove a wide variety of air contaminants, but are ineffective for 

some chemicals. CBRN APERs with carbon monoxide protection and heat and flame resistance are not 

commonly available. 

It is important to check the “wearability” of the APER hood to select the proper device for each potential 

user. Hoods that fit too tightly around the head or neck can contribute to feelings of claustrophobia or 

choking. To mitigate these problems, some CBRN APER hoods come in more than one size. 

63 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Manufacturers typically provide information on neck and/or head sizes that a particular APER hood 

might best fit. Manufacturers’ user instructions and training materials must be followed to select a 

properly fitting hood and for special instructions on how to don, wear, doff, and store the respirator. 

Training units (not intended to provide respiratory protection) are available to assist learning these 

activities. 

To determine proper fit, it is important to keep the following considerations in mind: 

 For APERs that contain an oral/nasal cup, it is important that the cup fits properly over the 

wearer’s nose and mouth to prevent the buildup of carbon dioxide inside the hood 

 If the wearer’s head is too large for the hood, it may not fit properly 

 If the wearer’s neck is small, the APER may not seal properly; if it is too large, the APER may 

choke the wearer 

 Some manufacturers require that the wearer cross-check the fit of the APER with another person 

Figure 3-18. CBRN APER with Blower. 

Courtesy ILC Dover. 

Approval Labels 

CBRN APERs with a 14G approval may be used for escape only from IDLH atmospheres that contain at 

least 19.5 percent oxygen. CBRN APERs should not be used to enter into, or to remain in, a contaminated 

environment. There are four NIOSH approval categories for CBRN APERs [NIOSH 2003b]: 

 General category consisting of multi gas/vapor and particulate protections: ammonia, cyanogen 

chloride, cyclohexane (organic vapors), formaldehyde, hydrogen cyanide, hydrogen sulfide, 

nitrogen dioxide, phosgene, phosphine, sulfur dioxide, GB, HD, and particulates (P100 particle 

filter) 

 General category with carbon monoxide (CO) protection 

 Specific category for chemicals and particulates in the general category with additional 

protections for any combination of the specific chemicals (e.g. additional protection for 

ammonia) 

 Specific category with CO protection 

64 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

The CBRN APER full NIOSH approval label, as explained for the other RPDs, contains the information that 

the user needs to consult to determine if an APER has been tested and certified by NIOSH for use in 

CBRN environments. This label is found in the manufacturer’s packaging or with the user instructions. 

The full NIOSH approval label and manufacturer’s user instructions must be carefully reviewed to 

determine the protections applicable to each APER model. 

In addition to the information shown on the NIOSH full approval label for all RPDs, the NIOSH full label 

for CBRN APERs should include the type and level of protection, as shown in Table 3-5. 

Table 3-5. CBRN APER Label Examples for Different Types of Protection 

Category Label Example 

APER with approval for 15-minute duration rating ESCAPE ONLY NIOSH CBRN 15 

APER with approval for a 15-minute duration rating 

with CO protections ESCAPE ONLY NIOSH CBRN 15 with CO 

APER receiving approval for a 30-minute duration 

rating with specific category 

ESCAPE ONLY NIOSH CBRN 30 with “chemical” 

Specific 

APER receiving approval for 30-minute duration, 

with specific category, and CO 

ESCAPE ONLY NIOSH CBRN 30 with “chemical” 

Specific and with CO 

Testing 

CBRN APERs are tested for permeation and penetration resistance with liquid and vapor aerosols of 

distilled HD and GB. LRPL tests are also conducted. Each one of these tests is explained in Chapter 2. 

NIOSH Cautions and Limitations Statements for CBRN APER 

At a minimum, NIOSH requires the C&L statements shown on Table 3-6 for CBRN APERs [NIOSH 2006a]. 

Table 3-6. NIOSH C&L Statements for CBRN APERs (Approval Schedule 14G) 

65 

A Not for use in atmospheres containing less than 19.5 percent oxygen. 

I Contains electrical parts that may cause an ignition in flammable or explosive atmospheres. 

(NOTE: Applies if the respirator contains electrical components and the intrinsic safety has not 

Been evaluated and approved by Mine & Safety Administration (MSHA) or a recognized 

Independent laboratory.) 

J Failure to properly use and maintain this product could result in injury or death. 

L Follow the manufacturer’s instructions for changing cartridges, canister, and/or filters. 

M All approved respirators shall be selected, fitted, used, and maintained in accordance with 

MSHA, OSHA, and other applicable regulations. 

O Refer to user instructions and/or maintenance manuals for information on use and maintenance 

of these respirators. 

R* Some CBRN agents may not present immediate effects from exposure, but can result in delayed 

impairment, illness, or death. 

S Special or critical user instructions and/or specific use limitations apply. Refer to user 

instructions before donning, due to unique or unusual design or critical operation requirements. 

X* Consult manufacturer’s user instructions for information on the use, storage, and maintenance 

of these respirators at various temperatures. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

AA This respirator is to be used for escape only and will protect against the inhalation of certain 

respiratory hazards. 

DD* This respirator provides respiratory protection against inhalation of certain gas and vapor 

chemical agents, biological particulates, and radiological and nuclear dust particles. This 

respirator provides limited dermal (skin) protection to the head area and eyes. 

EE* Eye irritation may be experienced based upon the CBRN agent and exposure (concentration and 

duration). 

GG* Direct contact with CBRN agents requires proper handling of the respirator after use. Correct 

disposal procedures must be followed. 

II* This respirator provides protection from certain inhalation hazards associated with fire. 

JJ* CBRN Agents, depending on how they are used, may provide a disabling effect as a result of skin 

exposure. 

NN* This respirator is a one-time-use device with no replaceable parts. Discard after use regardless 

of contaminant exposure. 

*CBRN-specific C&L. 

Figure 3-19. CBRN APER Packaging 

Packaging and Shelf Life 

Several types of packaging may be used for CBRN APERs: shipping boxes, storage boxes, carry pouches, 

and/or foil vacuum- sealed bags. The shelf life date is on the storage container and typically on the foil 

vacuum-sealed package. This is a time period for which the APER can be used if it is stored as specified 

by the manufacturer. 

All CBRN APERs are contained in a vacuum-sealed package to prevent the canister from being degraded 

by exposure to ambient conditions. The sealed packaging is normally protected by external packaging to 

prevent damage. CBRN APERs should remain sealed until needed for use. The APER should not be used if 

the expiration period has been exceeded, if the vacuum- seal is broken, or if the respirator is otherwise 

damaged. Examples of the CBRN APER packaging are shown in Figure 3-19. 

66 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Service Life and Useful Life Information 

Each CBRN APER is approved for a specified laboratory-rated service life. These service lives are 15, 30, 

45, or 60 minutes. The actual performance time during an escape depends on the breathing rate through 

the canister; specific type, volatility and concentration of the contaminants; and environmental 

conditions, such as humidity and temperature. Planning for potential hazards and evacuation routes is 

critical in selecting the most appropriate CBRN APER model. The service life required for a specific 

evacuation scenario should be determined by careful planning and trial exercises. 

In addition to its service life rating, each CBRN APER has a specified “useful life” period or shelf life 

printed on the CBRN APER label, as shown in Figure 3-20. The shelf or useful life of a CBRN APER is 

defined as the length of time a unit can remain deployed in the ready to use condition, as specified by 

the manufacturer. 

Figure 3-20. CBRN APER Useful Life Label 

It is important to note that “service life” (laboratory-rated duration) relates to performance, and “useful 

life” relates to reliability. These terms describe very different characteristics of CBRN APERs. The useful 

life of an escape respirator varies among manufacturers’ different APER models. It is important to 

carefully review and follow the manufacturer’s instructions for the specific CBRN APER in use. 

Potential CBRN APER users with certain medical conditions (e.g., asthma, chronic obstructive airway 

disease) may not be able to tolerate the increased breathing resistance of the APER. There is at least 

one APER available with a blower that may be suitable for these individuals. 

CBRN APERs require no maintenance and should not be removed from the protective packaging until 

used. After use, it should be properly discarded. Do not use the CBRN APER if the packaging is damaged 

in any way or if the expiration date is exceeded. 

Components for CBRN Air-Purifying Respirators 

CBRN PAPR Batteries 

Batteries are the power source for the CBRN PAPR blowers. Several different types of batteries are used 

by CBRN PAPR manufacturers. 

67 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

PAPR Battery Types 

Both rechargeable and non-rechargeable battery types used in CBRN PAPRs are listed in Table 3-7. 

General Battery Cautions and 

Limitations 

The manufacturers’ user instructions describe the proper care and conditioning required for the PAPR 

batteries. Failure to carefully follow these instructions may result in low performance of the PAPRs. To 

achieve the CBRN PAPR performance specified by the manufacturer and avoid personal injury, it is crucial 

that the batteries are properly stored, used, and conditioned (where applicable). In addition, because 

batteries contain chemicals to produce their rated voltage and ampere-hour capacities, proper disposal 

practices must be followed to prevent personal injury and damage to the environment. 

Table 3-7. Battery Types and Their CBRN PAPR Manufacturers 

Rechargeable Battery 

Battery Type PAPR’s Manufacturers 

Nickel-metal hydride (NiMH) 3M 

AirBoss 

AVON 

Dräger 

ILCD 

MSA 

SCOTT 

SEA 

Honeywell - SPERIAN 

Lithium Ion (Li-ion) AVON 

3M 

Alkaline (Zn/MnO2) Honeywell - SPERIAN 

ILCD 

Non-rechargeable Battery Type 

Lithium-Sulfur Dioxide (LiSO2) AirBoss 

AVON 

Dräger 

MSA 

SCOTT 

Honeywell – SPERIAN 

Lithium Manganese Oxide 

(LiMnO2) 

3M 

ILCD 

The NIOSH C&L statements required on approval labels for CBRN PAPRs do not directly address battery 

requirements such as storage, conditioning, usage, and disposal. However, the following NIOSH C&L 

statements, shown in Table 3-8, are indirectly associated with battery performance. 

68 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Table 3-8. NIOSH C&L Statements indirectly associated with batteries performances 

F Do not use powered air-purifying respirators if airflow is less than four (4) cfm (115 lpm) for 

tight-fitting facepieces or six (6) cfm (170 lpm) for hoods and/or helmets. 

Comment: If the batteries are not properly charged, these airflow rates may not be achievable. 

I Contains electrical parts that may cause an ignition in flammable or explosive atmospheres. 

Comment: Not all batteries used with CBRN PAPRs are intrinsically safe. 

J Failure to properly use and maintain this product could result in injury or death. 

Comment: If batteries are not stored and conditioned properly they can be damaged and cause 

personal injury. 

X Consult manufacturer’s user instructions for information on the use, storage, and 

maintenance of these respirators at various temperatures. 

Comment: Battery storage conditions and charging methods can adversely affect 

battery performance or damage the battery. 

O Refer to user instructions and/or maintenance manuals for information on use and 

maintenance of these respirators. 

Comment: It is very important to refer to the manufacturer’s user instructions and supplemental 

battery instructions (provided with the battery and battery charger) to properly store, condition, 

use, and dispose of batteries. 

Rechargeable Batteries 

Rechargeable NiMH batteries are widely used on NIOSH-approved CBRN PAPRs. Li-ion rechargeable 

batteries are less common, but the procedures for safe use and care are very similar to those for NiMH 

batteries. 

Some CBRN PAPRs can operate with either rechargeable or non-rechargeable batteries. It is important to 

review the user instructions of a particular CBRN PAPR to learn what type of battery the unit should use. 

Manufacturers may use different color battery caps or different length caps to help identify the correct 

battery that a particular CBRN PAPR will use, as shown in Figure 3-21. In no case should a battery not 

listed on the PAPR’s full NIOSH approval label be used. 

Battery life depends on many factors, including conditioning (if needed), maintenance, temperature, 

age, and number of charge/ discharge cycles. Spent CBRN PAPR batteries should be disposed of 

properly. The manufacturers’ user instructions provide information for proper disposal. 

Although batteries cannot be repaired, rechargeable batteries can be recharged and conditioned for 

reuse if they are in good condition. Manufacturers’ user instructions typically describe specific 

recharging and conditioning procedures. NIOSH-approved CBRN PAPRs must demonstrate a battery 

service life of at least four hours when tested on a breathing machine operating at 24 respirations per 

minute with a minute volume of 40 l/min [NIOSH 2008a]. 

69 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
NI

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

This performance is not guaranteed in use situations. The actual in-use service life of a CBRN PAPR will 

depend on a number of factors, including: 

 Charge level of the battery 

 Battery condition 

 Battery operating temperature 

 User workload 

 Resistance to airflow 

Figure 3-21. This NIOSH approved CBRN PAPR blower 

can be operated with different types of batteries. 

To identify the type of battery to be used, manufacturers supply 

battery covers of different colors or lengths. This picture shows 

the short cover for non-rechargeable batteries and the longer 

cover for rechargeable batteries. 

OSH -appr oved CBRN PAPRs must demonstrate a battery servicelifeo f at 

Manufacturers’ user instructions provide estimates of how long batteries will supply sufficient power to 

the CBRN PAPR in use, and describe procedures to check for proper airflow rate. Some CBRN PAPRs have 

battery or airflow indicators on the blower to alert the wearer when the flow rate falls below minimum 

required specifications. Alternatively, manufacturers may indicate a maximum length of time a CBRN 

PAPR can be used before leaving the contaminated environment to check the airflow rate or replace the 

battery. Other manufacturers may simply specify a minimum runtime (e.g., four hours for a NiMH 

battery). The instructions provided with the PAPR blower, battery, and/or battery charger will provide 

information on battery use, care, and storage. 

Battery Chargers 

Different types of battery chargers are available for CBRN PAPRs. These can include quick charge, trickle 

charge, post-trickle charge, and combinations of these. 

User instructions should be followed carefully to ensure proper battery performance and to avoid 

damage to the batteries. For example, some chargers are made to constantly condition (charge and 

discharge) batteries. 

70 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Thus, the batteries can remain in the charger until needed for use. Other chargers are made only to quick 

charge batteries. Batteries should be removed from these chargers when a full charge is achieved to 

avoid damage. 

Some manufacturers produce “gang” battery chargers, which can charge or condition multiple batteries. 

Heat is generated during the charging of a battery and must be dissipated to prevent overheating. Care 

must be taken to ensure there is ample ventilation where the charger is placed and sources of heat are 

not adjacent to the charger. 

Battery Service Life 

Rechargeable batteries can have a service life of several hundred discharge/charge cycles if properly 

used and maintained. Actual service life will vary, depending how the battery has been stored, used, and 

conditioned. Rechargeable batteries should not be completely discharged, as this can cause permanent 

damage. 

Acceptable temperatures for storage, operation, and charging vary among battery types and PAPR 

design. These temperatures are specified in the manufacturers’ user instructions. Exposing the PAPR and 

battery to temperatures outside the specified ranges can damage the battery or shorten its usable life. 

Temperature specifications for two CBRN PAPR manufacturers are shown in Table 3-9. Other 

manufacturers may specify different temperatures. 

Table 3-9. Sample Temperature Ranges for Storing, Using, and Charging Batteries 

Battery NiMH Li-Ion 

In Storage -4 to 115°F (-20 Below 86°F (30°C) 

to 45°C) 

Operating 10° to 120 °F (- Do not use above 

Charging 50° to 90°F (10 to Below 194°F 

Battery Recharging 

Periodic recharging is recommended to maintain fully charged batteries. Charging times vary, depending 

on the level of partial charge of the battery and charger characteristics. User instructions for 

recommended charging time should be followed. 

In many cases it is necessary to discharge batteries before recharging them. This is typically done by 

running the PAPR until the low battery warning comes on, or the airflow rate drops below the 

manufacturer’s specified level. Discharging is not necessary for battery chargers that are able to properly 

condition batteries through the discharge/charge cycle. Not all battery chargers have this capability. 

Battery Reconditioning 

New batteries, or batteries not used for extended periods, may require “reconditioning” before they can 

be fully charged. This generally involves subjecting the battery to several discharge and charge cycles. In 

most cases, batteries are discharged by connecting them to the PAPR blower and running it until the low 

battery or flow indicator indicates performance below required specifications. Manufacturers’ 

reconditioning procedures may differ from these general guidelines for specific PAPR batteries. 

71 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Disposal of Rechargeable Batteries 

Spent CBRN PAPR batteries must be recycled or discarded in accordance with federal, state, and local 

regulations. Manufacturers provide informationguidance for battery disposal procedures. The PAPR 

manufacturer’s instructions should be consulted for proper procedures. 

Non-rechargeable Batteries 

These three types of disposable batteries are currently used in CBRN PAPRs: 

 Alkaline 

 Lithium–SulfurDioxide (LiSO2) 

 Lithium-ManganeseDioxide (LiMnO2) 

Alkaline Batteries 

Alkaline cells are subject to both self- discharge and possible decomposition of the chemical contents. 

They should be kept cool or refrigerated during storage. A temperature range of 32 t o 50°F (0°C to 10°C) 

is optimal since it prevents freezing and overheating of the aqueous electrolyte. For prolonged storage, 

the batteries should be stored in vapor-proof packing to help alleviate the problem of electrolyte loss. 

Manufacturers may provide special containers for placing batteries in temporary storage. 

Commercially available, D-cell alkaline batteries can provide PAPR operating times up to 12 hours. 

Increased resistance to airflow through the cartridges or canisters from clogging can reduce the service 

time of the batteries. Only batteries within their expiration date should be used. 

LiSO2 Batteries 

LiSO2 batteries are designed for extended shelf life. A shelf life of 10 years or longer is possible if the 

batteries are stored in accordance with the manufacturer’s instructions. Fresh LiSO2 batteries should 

be kept in their original packaging until used. 

Ideally, LiSO2 batteries should be stored in a dry, cool environment. CBRN PAPR manufacturers’ user 

instructions specify acceptable ranges of temperature and humidity for batteries in storage. These 

recommendations are typically in the range of -22 to 131°F (-30 to 55°C). Heat sources such as furnaces 

and heating pipes should be avoided. 

LiSO2 single-use batteries can operate the CBRN PAPR up to eight hours under favorable conditions. 2 

However, after four hours of use, the user must leave the contaminated area, decontaminate if required, 

and check the PAPR airflow with cartridges installed according to the manufacturer’s instructions. 

Thereafter, the airflow must be checked at least every two hours of use. 

LiMnO2 Batteries 

LiMnO2 batteries are designed for extended shelf life. A shelf life of 10 years or longer is possible if the 

batteries are stored in accordance with the manufacturer’s instructions. Special battery storage 

containers may be available from some manufacturers. 

Manufacturersspecify acceptable ranges of temperature and humidity for LiMnO2 batteries in storage. 

Temperature extremes and exposure to heat sources should be avoided; a cool, dry storage area is 

desirable. 

72 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

LiMnO2 batteries may be used up to 12 hours under appropriate conditions. These batteries may have a 

label with a grid to mark the number of hours used. When the discharged batteries are exhausted, they 

should be prepared for disposal in accordance with their manufacturer’s instructions. Some 

manufacturers recommend checking the PAPR airflow using the same procedures and time intervals 

described above for LiSO2 batteries. 

2 

Alkaline batteries can be discarded with regular domestic waste in some locations. However, all batteries 

should be discarded or recycled in accordance with federal, state, and local regulations. 

Disposal of Non-rechargeable Batteries 

Non-rechargable LiSO2 batteries must be discarded on termination of use. They should be removed from 

the PAPR and discharged according to the manufacturer’s instructions. LiMnO2 batteries are generally 

not hazardous waste, and they are not regulated by the Department of Transporatation as hazardous 

materials. 

CBRN respirator manufacturers provide Specific instructions for disposal of non-rechargeable batteries 

and these instructions should be followed. 

CBRN PAPR Retrofit Kits 

In some cases, previously purchased NIOSH-approved 42CFR84 industrial PAPRs can be upgraded to 

provide CBRN PAPR protection. These upgrades must be performed using the manufacturer’s retrofit kit 

for a specific PAPR model. 

The upgrades must be performed in accordance with the manufacturer’s instructions to ensure the retrofit 

complies with the approved CBRN PAPR configuration, quality assurance, and performance requirements. 

PAPRs to be retrofitted must be in fully operational and protective condition, in service for no more than 

five years, and used for respiratory protection as part of an OSHA-compliant respirator program. 

The CBRN PAPR retrofit kit must, at a minimum, contain the following: 

 CBRN PAPR retrofit kit instructions 

 Replacement packaging, components, parts, materials, CBRN canisters or cartridges (as 

applicable), and operation instructions required to retrofit the PAPR to the identical 

configuration as the approved CBRN configuration level (including minimum packaging 

configuration for tight-fitting CBRN (PAPRs) 

 CBRN PAPR retrofit approval label(s)for the respirator retrofit kit 

Air-Purifying Respirators 

There are different accessory products available from manufacturers for CBRN APRs. Accessories such as 

outserts or covers for the facepiece lenses, rubber hoods, and voice amplifiers and extend user 

protection during a CBRN emergency. 

Some manufacturers will require the use of lens covers and skin to meet the CBRN approvals for a 

particular facepiece and it will be included in their package. In this case, these components are required 

for the RPD to be in the NIOSH-approved configuration and provide the specified protection. Other 

manufacturers’ facepieces may not need to have these outserts or lens covers to meet the requirements 

of the CBRN standards and they are optional accessories to provide an additional protection for the user. 

73 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

It is important to read the manufacturer 

user instructions and NIOSH approval 

labels to determine if the accessories are 

required components of an approved CBRN 

configuration or optional. 

Lens Covers 

Lens covers protect the standard facepiece lenses from impact or scratches. They are made of 

polycarbonate and normally come clear or shaded. These lens covers can easily be mounted on top of 

the facepiece lens to provide additional impact protection. This is a good accessory for a facepiece in 

which the lenses are of flexible design. Figure 3-22 shows a dark shade lense cover to conceal the face of 

the user. 

Figure 3-22. Shade lens cover. 

Courtesy MSA – The Safety Company 

Rubber Hoods 

Rubber hoods, as shown in Figure 3-23, provide additional protection to the protective clothing selected 

for the user involved in a CBRN event. 

Figure 3-23. Rubber hood. Courtesy 3M 

74 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Amplifier 

CBRN facepieces have a speaking diaphragm for better communication. Nevertheless, there are 

situations in which an amplifier attached to the facepiece will be of great convenience and allow for 

clearer communication among users during an emergency situation. 

Maintenance and Storage of CBRN RPDs 

CBRN SCBA 

All CBRN SCBAs must be maintained and tested in accordance with their manufacturer’s user 

instructions. Some procedures may only be performed by authorized service technicians using 

specialized equipment. Typical annual maintenance for CBRN SCBAs includes: 

 Regulator flow tests 

 Facepiece inspection and flow tests 

 Installation of upgrades 

There are other maintenance requirements regarding the hydrostatic cylinder check, which must be 

followed according to the user instructions and U.S. Department of Transportation regulations 

[Qualification, maintenance and use of cylinders, 2000]. Furthermore, SCBAs must be visually inspected 

and functionally tested as dictated by the manufacturer’s user instructions and OSHA regulations [OSHA 

1999]. OSHA also requires documentation of monthly inspections of all respirators maintained for 

emergencies. 

CBRN Air-Purifying Devices 

Routine maintenance requirements for the facepiece and other components of CBRN PAPRs, APRs, and 

APERs may differ among manufacturers. Some manufacturers require periodic testing of the complete 

facepiece on a pressure decay test apparatus. The user instructions must be strictly followed. 

Manufacturers may specify some maintenance procedures for many serviceable items that can only 

be performed by specially trained technicians or by the manufacturer. Repairs to CBRN PAPRs and APRs 

must be done using only components whose part numbers are listed on the full NIOSH approval label. 

Never substitute, modify, add, or omit parts. Use only exact replacement parts in the configuration as 

specified by the manufacturer. 

The user instructions must be consulted for the proper manner to store the tight-fitting CBRN PAPRs and 

APRs and their required components. Cleaning of the facepiece and its components must be done only 

with solutions recommended by the manufacturer. 

CBRN APERs are not intended to be serviced or repaired in the field. They are single-use devices and 

should never be reused. CBRN APERs must be stored and periodically inspected as specified by the 

manufacturer and OSHA. 

Storage instructions vary among manufacturers and models of APERs. The manufacturer’s user 

instructions describe storage conditions required to ensure the device is ready for use. Typical storage 

guidelines address the storage duration; acceptable ranges of temperature and humidity; protection 

from dust, dirt, sunlight, and chemicals; and protection from mechanical vibration, abrasion, and 

crushing. 

75 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

Summary 

CBRN RPDs have unique features that make them different from industrial respirators. CBRN respirators 

are designed to protect the user against a large number of highly toxic contaminants that may be 

present in a terrorist attack or accident. 

As discussed in this chapter, it is important to learn the unique features of a CBRN respirator and 

understand the NIOSH approval labels. These labels will guide the user in selecting appropriate and 

approved components to protect against CBRN contaminants. 

It is also important to understand the cautions and limitations of each device and component 

configuration. NIOSH C&L statements and manufacturer user instructions provide the necessary 

information. 

Finally, the manufacturer user instructions should be read carefully. They provide specific instructions 

and recommendations for the particular CBRN respirator. 

References 

Approval of respiratory protective devices. 42 CFR 84 (1995). 

BSI [1999]. BS EN 148-1:1999: Respiratory protective devices: threads for facepieces. Standard thread 

connection. German version. London, UK: British Standards Institution. 

NFPA [1997]. NFPA 1981: Standard on open-circuit self-contained breathing apparatus for the fire 

service. Quincy, MA: National Fire Protection Association. 

NFPA [2002]. NFPA 1981: Standard on open-circuit self-contained breathing apparatus for fire and 

emergency services. Quincy, MA: National Fire Protection Association. 

NFPA [2007]. NFPA 1981: Standard on open-circuit self-contained breathing apparatus (SCBA) for 

emergency services. Quincy, MA: National Fire Protection Association. 

NFPA [2013a]. NFPA 1404: Standard for fire service respiratory protection training. Quincy, MA: National 

Fire Protection Association. 

NFPA [2013b]. NFPA 472: Standard for competence of responders to hazardous materials/weapons of 

mass destruction incidents. Quincy, MA: National Fire Protection Association. 

NFPA [2013c]. NFPA 473: Standard for competence of ems personnel responding to hazardous 

materials/weapons of mass destruction incidents. Quincy, MA: National Fire Protection Association. 

NIOSH [1987]. Guide to industrial respiratory protection. By Bollinger NJ, Schutz RH. Morgantown, WV: 

U.S. Department of Health and Human Services, Centers for Disease Control, National Institute for 

Occupational Safety and Health, DHHS (NIOSH) Publication No. 87-116, 

https://www.cdc.gov/niosh/docs/87-116/pdfs/87-116.pdf 

76 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

NIOSH [1997] Letter to all interested parties. NIOSH service time recommendations for p-series 

particulate respirators. By Metzler RW. Pittsburgh, PA: US Department of Health and Human Services, 

Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/usernotices/notices/run-050297.html 

NIOSH [2002]. Statement of standard for Self-Contained Breathing Apparatus, Statement of Standard 

(attachment a). Pittsburgh, PA: Pittsburgh, PA: US Department of Health and Human Services, Centers 

for Disease Control and Prevention, National Institute for Occupational Safety and Health, http://www. 

cdc.gov/niosh/npptl/RespStandards/ ApprovedStandards/scba_cbrn. 

NIOSH [2003a]. Statement of standard for chemical, biological, radiological and nuclear (CBRN) airpurifying escape respirator (attachment a). Pittsburgh, PA: US Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, http://www. cdc.gov/niosh/npptl/standardsdev/cbrn/ escape/standard/aperstd-a. 

NIOSH [2003b]. Statement of standard for chemical, biological, radiological, and nuclear (CBRN) full 

facepiece air-purifying respirator (APR). Pittsburgh, PA: Pittsburgh, PA: US Department of Health and 

Human Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety 

and Health, http://www.cdc.gov/ niosh/npptl/standardsdev/cbrn/apr/ standard/aprstd-a. 

NIOSH [2006a]. List of NIOSH standard protections, cautions and limitations for approval labels. 

Pittsburgh, PA: US Department of Health and Human Services, Centers for Disease Control and 

Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/pdfs/CBRNPAPR/CLCompleteList3CBRNPAPR.pdf 

NIOSH [2006b]. Statement of standard for chemical, biological, radiological, and nuclear (CBRN) 

powered air-purifying respirators (PAPR). Pittsburgh, PA: Pittsburgh, PA: US Department of Health and 

Human Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety 

and Health, http://www. cdc.gov/niosh/npptl/standardsdev/cbrn/ papr/. 

NIOSH [2008a]. Determination of laboratory respirator protection level (LRPL) for CBRN self-contained 

breathing apparatus (SCBA) facepieces or CBRN air-purifying respirator (APR), standard testing 

procedure (STP). Pittsburgh, PA: US Department of Health and Human Services, Centers for Disease 

Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/stps/search.html. 

NIOSH [2008b]. Guidance on emergency responder personal protective equipment (PPE) for response to 

CBRN terrorism incidents. Pittsburgh, PA: US Department of Health and Human Services, Centers for 

Disease Control and Prevention, National Institute for Occupational Safety and Health, DHHS (NIOSH) 

Publication No. 2008-132, https://www.cdc.gov/niosh/docs/2008-132/ 

NIOSH [2016]. Standard respirator testing procedures. Pittsburgh, PA: US Department of Health and 

Human Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety 

and Health, https://www.cdc.gov/niosh/npptl/stps/respirator_testing.html. 

NIOSH [2017]. Certified equipment list. Pittsburgh, PA: US Department of Health and Human Services, 

Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/topics/respirators/cel/default.html 

77 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

CHAPTER 3 

CBRN RESPIRATOR EQUIPMENT 

OSHA [1999]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

OSHA [2006]. 29 CFR 1910.120 Hazardous waste operations and emergency response. Washington, DC: 

U.S. Department of Labor, Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9765. 

Qualification, maintenance and use of cylinders. 49 CFR 173.34 (2000). 

78 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

CHAPTER 4 – 

CBRN RESPIRATOR SELECTION 

Author: Larry Janssen 

Introduction 

Selection of the appropriate chemical, biological, radiological, and nuclear (CBRN) respirator for an initial 

emergency response is generally straightforward. In the majority of these situations, both the air 

contaminant and its concentration are unknown. Since any unknown environment can be immediately 

dangerous to life or health (IDLH), both safe practice and regulation [OSHA 1999] require that it be 

treated as such. As described in Chapter 2, only CBRN self-contained breathing apparatus (SCBAs) are 

certified for entry into IDLH atmospheres. Maximum skin protection (a totally encapsulating chemicalprotective suit) must also be used for unknown contaminants. This protective ensemble is commonly 

referred to as “Level A”protection. 

As information on the contaminant and its concentration are gathered during initial response, decisions 

can be made to establish site control (e.g., hot, warm, and cold zones) and determine appropriate CBRN 

respirators for remediation and ancillary work activities (such as crowd control and providing medical 

assistance to victims). This chapter describes the information and decision framework necessary to 

determine which CBRN respirator can be safely used for a given task. The same logic can also be used to 

determine if a CBRN device is suitable for an industrial environment. 

Selection Overview 

Four categories of information must be considered to select the correct respirator for use in any 

hazardous atmosphere: 

 Hazard analysis 

 Work area conditions 

 Human factors 

 Respirator capabilities and limitations 

The following sections describe how to address each category in the context of a CBRN response. 

Hazard Analysis 

At the point of notification of a potential CBRN incident, efforts to characterize the respiratory hazard 

should begin. Answers to basic questions about the physical state of the suspected agent (i.e., liquid, gas, 

or particle) can start the process of identifying the contaminant(s). Reports of odors, a description of the 

agent’s container or delivery device, and reports of symptoms of people exposed can provide useful 

clues to help identify the hazardous material. Oxygen deficiency must also be considered for incidents 

occurring in small indoor areas with limited natural ventilation. As noted earlier, if site entry must be 

made, the Level A ensemble with CBRN SCBA must be used. Direct-reading instruments should be used 

to measure oxygen content and, if possible, identify and quantify the contaminant and extent of 

contamination. 

79 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

In many cases, it may be necessary to collect air and/or bulk contaminant samples for laboratory analysis 

to make these determinations. Until the contaminant can be identified and its concentration measured or 

estimated, the only permissible respirator is the CBRN SCBA. When these steps are complete, further 

steps can be taken to determine if CBRN powered air-purifying respirators (PAPRs) or air-purifying 

respirators (APRs) can be safely used. 

As described in Chapter 2, CBRN PAPRs and APRs share approvals for particulate hazards (e.g., biological 

and radiological hazards), plus a wide range of chemical warfare agents (CWAs) and toxic industrial 

chemicals (TICs). Tables 4-1 through 4-4 display the CWAs and TICs covered by the CBRN approval. If the 

contaminant in question is covered by the CBRN approval, further analysis can determine if CBRN PAPRs 

and/or APRs are suitable to enter and work in the contaminated area. To make this decision, the 

following information is required: 

 An atmospheric concentration of the contaminant that is considered IDLH. These values can 

often be found in the NIOSH Emergency Response Safety and Health Database [NIOSH 2010a] or 

the NIOSH Pocket Guide to Chemical Hazards [NIOSH 2010b]. If the measured concentration 

exceeds the listed IDLH value, neither CBRN PAPRs nor CBRN APRs are acceptable. Only CBRN 

SCBAs can be used. 

 An atmospheric concentration of the contaminant that is defined as acceptable, generally called 

an occupational exposure limit (OEL). For most TICs, these values are listed as Recommended 

Exposure Limits (RELs), Threshold Limit Values (TLVs©), and Permissible Exposure Limits (PELs). 

These values can be found in one or more commonly available references [ACGIH 1991; NIOSH 

2010b; OSHA 2010a]. Equivalent information for CWAs can often be found in the NIOSH 

Emergency Response Safety and Health Database [NIOSH 2010a]. (Note: Because OELs do not 

exist for biological hazards, NIOSH makes specific, risk-based protective ensemble 

recommendations for these materials) [NIOSH 2009]. 

 Once a measured or estimated contaminant exposure is determined, it is divided by the selected 

limit of acceptable exposure to determine the hazard ratio (HR): 

The HR describes how much reduction in airborne exposure (i.e., protection) the selected 

respirator must provide. 

 Assigned protection factors (APFs) for CBRN respirators. 

APFs represent the level of respiratory protection that a class of respirators is expected to 

provide to employees when a continuing, effective respiratory protection program is in 

place [OSHA 1999]. 

Note that APFs cannot be used if an effective respiratory protection program is not in place. 

Stated mathematically, APFs are the ratio of the contaminant concentration outside the respirator (Co) 

to the maximum amount of contamination expected to penetrate to the inside of the respirator (Ci): 

80 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Most employers and responder organizations in the United States are regulated by the Occupational 

Safety and Health Administration (OSHA) or an equivalent state agency. The APFs OSHA lists for CBRN 

respirators are shown in Table 4-5. A CBRN respirator with an APF equal to or greater than the calculated 

HR can be selected for contaminant concentrations below the IDLH value. 

Table 4-1. Chemical Warfare Agents and Toxic Industrial Chemicals Covered by the CBRN 

Approval—Organic Vapors* 

A through C D through F G through L 

Acetone cyanohydrin 

Acrylonitrile 

Allyl alcohol 

Allyl chlorocarbonate 

Bromoacetone 

Bromobenzylcyanide 

Chloroacetone, 

Chloroacetonitrile, 

Chloroacetophenone, 

Chloroacetophenone/ 

chloroform/ 

chloropicrin (23/38.4/38.4) 

Chloroacetyl chloride 

Chloropicrin 

Chloropivaloyl chloride 

Crotonaldehyde 

Cyclohexyl methyphosphonate 

Dibenz-(b,f)-1,4-oxazepine 

Diketene 

Dimethyl sulfate 

Diphenylcyanoarsine 

Distilled mustard (HD) 

Ethyl chloroformate 

Ethyl chlorothioformate 

Ethyl phosphorodichloridate 

Ethylene dibromide 

Hexachlorocyclopentadiene 

Hexaethyl tetraphosphate 

Iso-butyl chloroformate 

Iso-propyl chloroformate 

Lewisite 

M through O P through R S through Z 

Methanesulfonyl chloride 

Methyl orthosilicate 

Methyl parathion 

Mustard-lewisite mixture 

Nitrogen mustard HN-1 

Nitrogen mustard HN-2 

Nitrogen mustard HN-3 

N-propyl chloroformate 

O-chlorobenzylidene 

malononitrile 

Parathion 

Perchloromethyl mercaptan 

Phenyl mercapatan 

Phenylcarbylamine chloride 

Phenyldichloroarsine 

Phosgene 

oximedichloroforoxime 

Sarin 

Sec-butyl chloroformate 

Soman 

Tabun 

Tert-octyl mercapatan 

Tetraethyl dithiopyrophosphate 

Tetramethyl lead 

Tetranitromethane 

Trimethoxysilane 

Trimethylacetyl chloride 

VX 

* Other organic vapors are included in this approval if adequate service life can be shown. 

81 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Table 4-2. Chemical Warfare Agents and Toxic Industrial Chemicals Covered by the CBRN 

Approval—Acid Gases 

A through C D through F G through L 

Boron tribromide 

Boron trichloride 

Boron trifluoride 

Bromine 

Bromine chloride 

Bromine pentafluoride 

Bromine trifluoride 

Carbonyl fluoride 

Chlorine 

Chlorine pentafluoride 

Chlorine trifluoride 

Chlorosulfonic acid 

Cyanogen chloride 

Dichlorosilane 

Ethyl phosphonous dichloride 

Fluorine 

Hydrogen bromide 

Hydrogen chloride 

Hydrogen cyanide 

Hydrogen fluoride 

Hydrogen iodide 

Hydrogen selenide 

Hydrogen sulfide 

Phosgene 

Phosphorus trichloride 

M through O P through R S through Z 

Phosgene 

Phosphorus trichloride 

Silicon tetrafluoride 

Sulfur dioxide 

Sulfur trioxide 

Sulfuric acid 

Sulfuryl chloride 

Titanium tetrachloride 

Tungsten hexafluoride 

Table 4-3. Chemical Warfare Agents and Toxic Industrial Chemicals Covered by the 

CBRN Approval—Other Gases 

Base Gases Nitrogen Oxides Hydrides 

Allyl amine Nitric acid Arsine Formaldehyde 

Ammonia Fuming nitric acid Germane 

1,2-dimethyl hydrazine Nitric oxide Phosphine 

Methyl hydrazine Nitrogen dioxide Stibine 

Nitrogen tetraoxide 

Nitrogen trioxide 

82 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Table 4-4. Chemical Warfare Agents and Toxic Industrial Chemicals Covered by the 

CBRN Approval—Particles† 

Particulate Chemicals Biological Hazards* 

(Disease and Causative Agent) 

Radiological Hazards 

Adamsite 

Sodium azide 

Sodium fluoroacetate 

Anthrax (Bacillus anthracis) Botulism 

(Clostridium botulinum) Brucellosis 

(Brucella species) Glanders 

(Burkholderia mallei) Pneumonic 

Plague (Yersinia pestis) Query (Q) 

Fever (Coxiella burnetii) Ricin (Toxin 

found in Castor beans) Smallpox 

(Variola virus) Staphylococcus 

enterotoxin B (Toxin produced by 

Staphylococcus aureus) T-2 

Mycotoxins (Toxins produced by 

molds, e.g., Fusarium, Stachybotrys) 

Tularemia (Francisella tularensis) 

Venezuelan equine encephalitis 

(Alphavirus species) 

Viral hemorrhagic fevers 

(Arenaviridae viruses) 

Americium 241 

Carbon 14 

Cesium 137 

Cobalt 60 

Hydrogen 3 (Tritium oxide) 

Iodine 131 

Nickel 63 

Phosphorous 32 

Plutonium 239 

Promethium 147 

Radium 226 

Strontium 90 

Technetium 99m 

Thallium 204 

Thorium 232 

Uranium 235 & 238 

†All particulate hazards are included in this approval. 

*See reference 6 for specific protective equipmentrecommendations.. 

Table 4-5. Assigned Protection Factors (APFs) for CBRN Respirators 

CBRN Respirator Type APF 

Self-contained breathing apparatus (SCBA) 10000 

Powered air-purifying respirator (PAPR) 1000 

Air-purifying respirator (APR) 50 

Example, Part 1: 

Responders wearing CBRN SCBAs have identified a liquid spilled in a store room as allyl alcohol. After 

securing the area and performing initial clean-up, an airborne concentration of 5 parts per million (ppm) 

remains. Additional clean-up of the area is expected to take 3 hours. The NIOSH REL for allyl alcohol is 2 

ppm (up to 10 hour exposure) and the IDLH concentration is 20 ppm. What is the minimum acceptable 

CBRN respirator for the clean-up crew? 

Solution: 

The allyl alcohol concentration is below the IDLH value, but greater than the REL. The hazard ratio is 

calculated as: 

From Table 4-5, both the CBRN PAPR and CBRN APR have APFs greater than the hazard ratio. Allyl 

alcohol is an organic vapor covered by both CBRN approvals. The CBRN APR is the minimum acceptable 

respirator if a canister change schedule is developed and implemented (see discussion below). 

These portions of the selection process are summarized graphically in Figure 4-1. 

83 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Work Area Conditions, Human Factors and Respirator Considerations 

The protective capability of a CBRN respirator is only one consideration in the selection of a “most 

appropriate” device in a specific situation. The physical layout of the work (or response) area, 

environmental conditions such as temperature extremes and humidity, and the level of work effort 

required can act alone or in combination to affect which CBRN respirator is most suitable. For example, 

while CBRN SCBAs can be highly protective, they are not well-suited to long-term use because of their 

limited service life. Their bulk makes their use in confined or cluttered work areas difficult, and their 

weight adds significantly to cardiovascular stress. The combination of heavy work, high temperature, and 

full-body protective ensembles can contribute to physical stress as well. CBRN PAPRs mitigate the 

problems of weight and bulk, but they are not suitable for all contaminants. Battery service time, 

charging, and maintenance must be considered. Additionally, the service life of the canister or cartridge 

must be estimated and a change schedule developed. 

While they are the simplest and lightest of CBRN respirators, APRs have the same canister concerns as 

PAPRs. Since air is drawn through the canister by the wearer’s inhalation, they can have significant 

breathing resistance, which can add to physical stress and reduce worker comfort. Finally, any respirator 

must be selected to maximize compatibility with the remainder of the protective ensemble. 

Duration of Use of CBRN Respirators 

Four “duration values” are associated with CBRN respirators: 

1. The 2-hour, 6-hour, or 8-hour use limitation on CBRN devices exposed to CWAs. As described in 

Chapter 2, the limitation that applies is based on the type of CBRN device and whether the CWA 

exposure is to the liquid or vapor state. 

2. The nominal duration of the breathing air supply of a CBRN SCBA (i.e., 30, 45, or 60 minutes). These 

values are based on laboratory testing and are not accurate predictors of how long users will receive 

air from the devices. For example, high work rates shorten SCBA service time substantially. 

3. The rated capacity of PAPR and APR canisters and cartridges (i.e., CAP1 = 15 min, CAP2 = 30 min, etc.). 

These values indicate how long the air-purifying elements prevent breakthrough (i.e., detection 

downstream of the cartridge or canister) of specific test agents under stated laboratory conditions 

(see Chapter 2). They do not predict how long the canisters or cartridges will last in actual use when 

contaminants and their concentrations, as well as environmental conditions differ from the test 

conditions. 

4. The canister or cartridge end-of-service-life indicator (ESLI) or change schedule. Because ESLIs are not 

yet available on any CBRN device, a change schedule must be determined whenever CBRN PAPRs or 

APRs are used [NIOSH 2006]. This is simply the time interval at which the canister(s) or cartridge(s) 

are replaced with new ones, and it must be established based on the site-specific conditions of use. It 

should also be noted that the same requirement is found in the OSHA respiratory protection 

regulation [OSHA 1999]. 

84 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 
 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Figure 4-1. CBRN Respirator Selection for Entry into Contaminated Atmosphere

Shown to Contain 19.5%–23.5% Oxygen 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 85 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Canister/Cartridge Change Schedules 

Change schedules are separate from CAP ratings. They must be based on objective data, ensuring the 

canisters or cartridges are changed before contaminant breakthrough. The data necessary to set a 

change interval include estimates of: 

 The specific CBRN device in use 

 The air contaminant(s) and its concentration at the worksite 

 Environmental conditions, including temperature and relative humidity 

 Work rate or PAPR airflow rate 

 Acceptable breakthrough concentration 

 Appropriate safety factors 

Determination of the breakthrough time for a specific set of conditions is best done 

using computer applications or equivalent tools developed by CBRN respirator 

manufacturers [3M 2010; MSA 2010; Scott 2010]. 

Different manufacturers’ canisters may have different physical characteristics and different sorbents, 

and their software may use different assumptions or default values when performing calculations. 

For these reasons, each manufacturer’s software must be considered unique to its own CBRN devices 

and cannot be used to estimate breakthrough time for another manufacturer’s device. It is critical to 

work with the manufacturer before an incident occurs to learn which breakthrough estimation tools are 

available and how to use them. If an incident should occur, the breakthrough time can be quickly 

determined for the site-specific conditions. This estimate can then be used to set a change schedule that 

is both protective (i.e., it ensures users are not exposed to hazardous contaminant concentrations) and 

administratively feasible (i.e., it coincides with users’ break times or end of the work shift). 

Example, Part 2: 

A CBRN CAP1 APR was selected for the allyl alcohol clean-up crew in Part 1 of this example. The 

Cartridge Life Calculator [MSA 2010] was used to estimate breakthrough time with the following 

assumptions: 

Inlet concentration: 5 ppm allyl alcohol 

Environmental conditions Temperature: 68°F Relative humidity: 60% 

Atmospheric pressure: 760 Torr 

Work (breathing) rate: 60 L/min 

(moderate work rate) 

No safety factor selected 

Calculated service time to 10% of OEL: 8108 minutes 

Change schedule: The estimated breakthrough time is well beyond the 180 minutes the respirators are 

expected to be used. The canisters should be discarded at the end of the task in accordance with 

procedures described in Chapter 8. This allows a very large margin of safety to account for uncertainty in 

the assumptions used for the calculation. Used canisters should not be kept for use beyond a single shift, 

regardless of the estimated breakthrough time. This is because organic vapors may desorb from (come 

off) the activated carbon during periods of nonuse. The vapors may migrate through the bed and 

potentially expose the wearer to the contaminant if reused. Desorption and migration are most likely to 

occur with organic vapors with relatively low boiling points (< 65°C). 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 86 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

If manufacturer applications to estimate breakthrough times for organic vapors are not available, OSHA and 

NIOSH both offer service life calculators [NIOSH 2010c; OSHA 2010b]. In addition to the input data 

manufacturers’ applications require, these programs require the user to enter data on the physical 

characteristics of the canister or cartridge in use, as well as specific characteristics of the activated carbon it 

contains. If either of these programs is to be used, it is still necessary to work closely with the respirator 

manufacturer before an incident occurs to ensure the end user has the necessary information. 

If other information is not available, a rough estimate of breakthrough time can be made using information 

from NIOSH testing and worksite conditions. This might be the case, for example, if for emergency reasons, an 

APR canister from one manufacturer is used on another manufacturer’s facepiece. As described in Chapter 2, 

canisters and cartridges are tested with test representative agents (TRAs) for six families of gases and vapors. 

An underlying assumption is that each TRA will have a breakthrough time no greater than other members of its 

family [NIOSH 2004]. Therefore, a breakthrough estimate can be made for all members of a family using the 

TRA as a surrogate for the family member. A simple ratio of the NIOSH challenge concentration to the site 

concentration, multiplied by the minimum required breakthrough time in the NIOSH certification test provides 

a rough estimate of how long a canister or cartridge will last before breakthrough. Because service time is 

inversely proportional to flow rate [Colton and Nelson 1997], it is acceptable to adjust the result for breathing 

rates significantly higher or lower than the test flow rate of 64 L/min. This procedure was compared with two 

manufacturers’ software breakthrough estimates for their respective CAP1 canisters over a range of 

cyclohexane concentrations. Input conditions were 60 L/min breathing rate, sea level pressure, and 60 percent 

relative humidity. Figure 4-2 shows that the results were similar at each concentration, with the simple ratio 

method at or near the shortest breakthrough estimate. This method must be used with caution, and 

appropriate safety factors applied when setting a change schedule. 

Figure 4-2. Estimated Breakthrough Times for Cyclohexane 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 87 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Example, Part 3: 

A generic CBRN CAP1 APR was selected for the allyl alcohol clean-up crew in Part 

1 of this example. The organization cannot locate specific service life information or data to allow use of the 

OSHA or NIOSH service life calculators. A rough estimate of service life can be made as follows: 

Inlet concentration: 5 ppm allyl alcohol (now assumed to be 5 ppm cyclohexane) 

Work (breathing) rate: 60 L/min (moderate work rate) 

Change schedule: The estimated breakthrough time is well beyond the 180 minutes the respirators are 

expected to be used, even with a safety factor of 3 to account for the use of a surrogate vapor and the 

very approximate nature of the method used. The canisters should be discarded at the end of the task. 

Users must recognize that a change schedule represents an estimated maximum amount of time that 

cartridges or canisters should be used. Replacement must be done before the scheduled time if a 

wearer detects chemical odor or experiences symptoms of exposure, or if the respirator is damaged 

in any way. 

Industrial Use of CBRN Respirators 

As noted earlier in this chapter, the same selection considerations apply to both CBRN and industrial 

respirator use. CBRN APRs hold an advantage in the broad range of contaminants for which they are 

tested and approved, and are approved for some contaminants for which industrial APRs are not 

commonly available (e.g., phosgene). However, CBRN devices tend to be larger, heavier than cartridgestyle industrial respirators, and CBRN APRs may have higher breathing resistance. All of these can add 

unnecessary physiological burden to the wearer. Higher cost may also be a disadvantage of CBRN 

devices. 

Air-Purifying Escape Respirators 

Air-purifying escape respirators (APERs) are tested and approved for escape only from the same air 

contaminants as are CBRN PAPRs and APRs, and might also be approved for carbon monoxide. It must be 

emphasized that “escape” refers to the act of leaving the contaminated area as quickly as practical to 

get to respirable air [Janssen 2001]. Entry into a contaminated area or performing work of any sort is not 

permitted while using an APER. 

There is no specific regulation or guideline that dictates when CBRN APERs should be made available. 

Careful hazard analysis is necessary to identify when or if these devices would enhance worker 

protection during escape from a contaminated atmosphere. Particular emphasis must be placed on the 

identity of the potential air contaminant (i.e., will it be removed by an APER) and the time required to 

reach a respirable atmosphere. Identification of potential evacuation routes is essential to make this 

determination. Assigned protection factors and requirements for change schedules do not apply to APER 

selection and use. As is the case with any respirator selection, fit, training requirements, and use 

characteristics of individual APER products must be considered before a specific device is purchased. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 88 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

Summary 

The factors that influence selection of CBRN respirators are the same as those that affect respirator 

selection in any work environment. Users must understand these principles and the unique 

characteristics of CBRN respirators to make the most appropriate selection for a given set of use 

conditions. All respirators chosen must be used in the context of a complete respiratory protection 

program. 

References 

3M [2010]. Service life software. Maplewood, MN: The 3M Company. 

http://extra8.3m.com/SLSWeb/serviceLifeDisclaimer.html?reglId=20&langCode=EN&countryName=Unit 

ed%20States 

ACGIH [1991]. Threshold limit values for chemical substances and physical agents and biological 

exposure indices. Cincinnati (OH): American Conference of Governmental Industrial Hygienists. 

Colton C, Nelson T [1997]. The occupational environment-its evaluation and control: respiratory 

protection. Fairfax , VA. AIHA Press p. 974-1000 

Janssen L [2001]. Respiratory protection-a manual and guideline (3rd ed): Emergency escape respirators. 

Fairfax , VA. AIHA Press p. 71-74. 

MSA [2010]. Cartridge life expectancy calculator. Cranberry Twp, PA: MSA The Safety Company. 

http://webapps2.msasafety.com/responseguide/Home.aspx 

NIOSH [2004]. Concept for CBRN full facepiece air purifying respirator (APR) standard. Cincinnati, OH: 

U.S. Department of Health and Human Services, Centers for Disease Control and Prevention, National 

Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/standardsdev/cbrn/apr/concepts/aprcon-081902.html. 

NIOSH [2006]. List of NIOSH standard protections, cautions and limitations for approval labels. 

Cincinnati, OH: U.S. Department of Health and Human Services, Centers for Disease Control and 

Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/pdfs/CBRNPAPR/CLCompleteList3CBRNPAPR.pdf 

NIOSH [2009]. Recommendations for the selection and use of respirators and protective clothing for 

protection against biological agents. Atlanta, GA: U.S. Department of Health and Human Services, Public 

Health Service, Centers for Disease Control and Prevention, National Institute for Occupational Safety 

and Health, DHHS (NIOSH) Publication No. 2009-132, https://www.cdc.gov/niosh/docs/2009-

132/default.html 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 89 
 

 

 

 

 

 

 

 

CHAPTER 4 

CBRN RESPIRATOR SELECTION 

NIOSH [2010a]. The emergency response safety and health database. Cincinnati, OH: U.S. Department of 

Health and Human Services, Centers for Disease Control and Prevention, National Institute for 

Occupational Safety and Health, https://www.cdc.gov/NIOSH/ershdb. 

NIOSH [2010b]. Pocket guide to chemical hazards. Cincinnati, OH: U.S. Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, https://www.cdc.gov/niosh/npg 

NIOSH [2010c]. Multivapor version 2.2.3. Pittsburgh, PA: U.S. Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, https://www.cdc.gov/niosh/npptl/multivapor/multivapor.html 

OSHA [1999]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

OSHA [2010a]. 29 CFR 1910.1000-1052 Toxic and hazardous substances. Washington, DC: U.S. 

Department of Labor, Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9991 

OSHA [2010b]. The advisor genius: selecting an appropriate respirator. Washington, D.C. Occupational 

Safety and Health Administration 

https://www.osha.gov/SLTC/etools/respiratory/respirator_selection_advisorgenius.html 

Scott [2010]. SureLife cartridge calculator. Monroe, NC: Scott Safety. 

https://www.scottsurelife.com/DesktopUI/SelectRegion.aspx 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 90 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

CHAPTER 5 – 

CBRN RESPIRATORY PROTECTION 

PROGRAM REQUIREMENTS 

Author: James S. Johnson 

Introduction 

Emergency responder organizations (including law enforcement, fire fighters, and emergency medical 

technicians) that respond to chemical, biological, radiological, and nuclear (CBRN) and other hazardous 

material emergencies where respirators are needed are required to implement a respiratory protection 

program as defined in: 

Occupational Safety and Health Administration (OSHA) Respiratory Protection regulation, 29 Code of 

Federal Regulations (CFR) 1910.134 [OSHA 1999] 

The OSHA Hazardous Waste Operations and Emergency Response regulation, 29 CFR 1910.120 

[OSHA 1990] 

The Environmental Protection Agency (EPA) Worker Protection regulation, 40 CFR Chapter 1, Part 311 

[Worker protection, 2011] also clearly identifies the OSHA Respiratory Protection regulation, 29 CFR 

1910.134, as a requirement for organizations that respond to CBRN and other hazardous material 

incidents. National Fire Protection Association (NFPA) 472, “Standard for Competence of Responders to 

Hazardous Material/Weapons of Mass Destruction Incidents,”[NFPA 2013a] and NFPA 473, “Standard 

Competencies for EMS Personnel Responding to Hazardous Materials/ Weapons of Mass Destruction 

Incidents” also reference this standard [NFPA 2013b]. 

T.K. Cloonan, a physical scientist at NPPTL, presented his findings on the use of CBRN respiratory 

protection equipment by a number of large U.S. fire and police departments. As part of this unique 

assessment of 155 organizations, he interacted directly with these organizations and evaluated the 

current content and implementation of their CBRN respiratory protection programs [Cloonan 2011]. In 

his interaction with the 42 fire service organizations contacted, he noted: 

U.S. Tier I fire service organizations continue to use variations of written/ non-written 

respiratory protection programsa 

U.S. Tier II and III cities rely on partial/incomplete respiratory protection programs through the 

use of policy letters; standard operating procedures (SOPs); and standards, objectives, and goals 

(SOGs)a 

The use of written respiratory protection programs is not as common in states that have not 

implemented a state OSHA program 

“NIOSH-approved” is misunderstood; many incorrectly equate it with NIOSH- approved CBRN 

protection 

Field self-contained breathing apparatus upgraded to CBRN Agent Approved (retrofit) require 

quality assurance inspections to ensure the upgrade was done correctly 

a Tier I through Tier III classification refers to various Homeland Security risk assessment processes [Cummings et 

al. 2016]. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 91 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

In his interaction with the 15 law enforcement organizations contacted, Cloonan noted: 

Written respiratory protection programs are in development, FBI HAZMAT response continues to 

set the readiness standard, and CS (tear gas) is still being used for respiratory protection training 

Police departments require respiratory protection from the effects of clandestine drug labs, 

hydrogen sulfide suicide incidents, and biological powder incidents 

Cloonan’s findings identify the need to develop a compliant respiratory protection program for CBRN 

applications for various emergency responder organizations. 

The purpose of a CBRN respiratory protection program is to provide an organized set of elements that 

must be implemented to ensure the correct and functional CBRN respiratory protection is provided to 

the informed and trained respirator user. CBRN respiratory protection programs provide a safety net 

for emergency responders and ensure they are properly qualified and trained and their equipment is 

properly selected and maintained. Proper training and selection will protect them in emergency 

situations. 

The need for various respiratory protection program elements was first recognized in a 1938 American 

Standard Safety Code [ASA 1938] and expanded in a 1959 revision of that code [ASA 1959]. The specific 

requirement for a comprehensive respirator program was first specified in the American National 

Standards Institute (ANSI) Z88.2-1969 Standard, “Practices for Respiratory Protection,”[ANSI 1969] which 

was adopted by OSHA as 1910.134 in 1971 [OSHA 1971]. This OSHA respiratory protection regulation 

was revised in 1998 [OSHA 1998] and 2006 [OSHA 2006]. There are currently nine elements in an OSHAcompliant CBRN respiratory protection program that need to be addressed. These program elements 

are: 

1. Procedures for selecting respirators for use in the workplace 

2. Medical evaluations of employees required to use respirators 

3. Fit testing procedures for tight-fitting respirators 

4. Procedures for proper use of respirators in routine and reasonable foreseeable emergency 

situations 

5. Procedures and schedules for cleaning, disinfecting, storing, inspecting, repairing, discarding, and 

otherwise maintaining respirators 

6. Procedures to assure adequate air quality, quantity, and flow of breathing air for atmospheresupplying respirators 

7. Training of employees in respiratory hazards to which they are potentially exposed during routine 

and emergency situations 

8. Training of employees in the proper use of respirators, including putting on and removing them, 

any limitation of their use, and their maintenance 

9. Procedures for regularly evaluating the effectiveness of the program 

This written respiratory protection program is required to be updated on a regular basis to reflect changes 

in the workplace. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 92 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

This chapter addresses each of these program elements; some of them will be expanded in separate 

chapters of this handbook. To implement each respiratory protection program element, organizations 

typically prepare a standard operating procedure (defined as a set of written instructions to document a 

routine or repetitive activity followed by the organization) for each program element. The benefit of 

developing SOPs for each respiratory protection program element is that it minimizes variation and 

promotes quality through consistent implementation of well-defined procedures. Specific reference 

documents are available to provide recommendations in the preparation of SOPs [EPA 2007; FEMA 1999; 

SAFECOM 2006]. 

CBRN Respiratory Protection Program Elements 

General Requirements 

OSHA requires the employer to designate a respiratory protection program manager who is the one 

person responsible to administer or oversee the CBRN respirator protection program. The qualifications 

for this individual can be met by appropriate experience and training commensurate with the complexity 

of the program. This individual should have a management position or rank that allows the appropriate 

interaction with other parts of the organization assigned responsibility for any of the program elements. 

Emergency responders must only use NIOSH-approved respirators such as CBRN self-contained 

breathing apparatus (SCBAs), powered air- purifying respirators (PAPRs), full facepiece air-purifying 

respirators (APRs) (gas masks), and air-purifying escape respirators (APERs). Use of these respirators 

requires a complete respiratory protection program. 

The employer is required to provide CBRN respirators, training, and medical evaluations at no cost to the 

employee. 

Procedures for Selecting Respirators for Use in a CBRN Response 

Written procedures for CBRN respirator selection must be comprehensive, task specific, and updated on 

a regular basis. These procedures are not intended only to meet a regulatory requirement and placed on 

a shelf. They need to be of value at the working level and referred to on a regular basis. For many 

organizations, checklists are used to present the information in an easy-to-use format. 

The hazards assessment process is a very important part of respirator selection. Factors that should be 

considered when completing the hazards assessment for toxic materials such as CBRN agents are: 

Physical and chemical properties 

Adverse health effects 

Occupational exposure level 

Results of workplace sampling 

Work operation 

Time period of respirator wear 

Work activities and stresses on the wearer 

Warning properties 

Capabilities and limitations of CBRN respirator types 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 93 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

Chapter 4 on CBRN respirator selection addresses these four categories of information: hazard analysis, 

work area conditions, human factors, and respirator capabilities. This chapter provides more detailed 

information about the respirator selection process and these four categories of information, including 

specific examples of how to utilize them for respirator selection. 

Medical Evaluations of Employees Required to Use CBRN Respirators 

Medical evaluations are required to ensure workers can safely wear a specific type of respirator. This 

initial medical evaluation can be completed several different ways following OSHA recommendations. 

The initial step of filling out the OSHA Medical Evaluation Questionaire (OSHA 1910.134, Appendix C) can 

be done by the employee, or with the help of a physician or other licensed health care professional 

(PLHCP). The answers are reviewed by the PLHCP and any additional tests the PLHCP feels necessary for 

the evaluation are administered. The employer is also required to provide the PLHCP with the following 

information: 

The type and weight of the respirator being used 

The duration and frequency of use (including use during rescue and escape) 

The expected physical work effort 

Additional protective clothing and equipment to be worn 

Temperature and humidity extremes that may be encountered 

A copy of the written respirator program 

The PLHCP reviews all of this information and provides the employer with a determination for each 

employee, including whether the employee cannot use a respirator (no usage), full respirator usage, or 

limited respirator usage (with specific restrictions). Assessing the ability of the worker to safely tolerate 

the physiological burden created by wearing a CBRN respirator is the purpose of the medical evaluation. 

Additional information on this subject is provided in Chapter 8. The pre-placement medical evaluation 

must be completed prior to fit testing and the use of any respirator. Additional medical evaluations are 

not required at a specific time interval, but must be provided based on observations or a request by the 

PLHCP, respirator program administrator, respirator fit tester, supervisor, or the worker. An additional 

evaluation is also required if the worker is assigned to a different job with a greater physiological burden 

(e.g., higher work rate, additional protective clothing, or higher temperatures). 

Specific medical evaluation requirements for the Fire Service are provided in NFPA 1582, “Standard On 

Comprehensive Occupational Medical Program for Fire Departments.”[NFPA 2013d] ANSI Z88.6-2006, 

“American National Standard for Respiratory Protection-Physical Qualifications for Respirator Use,”[ANSI 

2006] provides additional information related to medical evaluations for workers required to use 

respirators. 

Fit Testing Procedures for Tight-Fitting CBRN Respirators 

Respirator fit testing is a very important part of the respiratory protection program because it confirms 

and documents that the specific respirator model selected for the worker fits properly. OSHA requires 

that a worker receive an initial fit test before beginning work using the same make, model, style, and size 

of respirator that will be used in the workplace. Fit testing also provides a good opportunity to train the 

worker on how to don and wear the respirator properly. The results of improper donning can be 

demonstrated quickly by smell, taste, or with direct readout instrumentation. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 94 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

There are two general types of fit testing techniques: qualitative and quantitative. Qualitative fit testing 

utilizes the worker’s senses of taste or smell of the test agent to determine if a proper respirator fit has 

been achieved. 

Quantitative fit testing, on the other hand, uses a separate analytical instrument to determine if there 

has been a measurable leak of the respirator. 

Additional fit testing is required when a different respirator facepiece (size, style, model, or make) is 

used, or at least annually after the initial test. Additional fit tests must also be provided when 

observations are made that identify changes in the respirator user’s physical condition that could affect 

respirator fit. Such conditions include, but are not limited to, facial scarring, dental changes, cosmetic 

surgery, facial piercings, or an obvious change in body weight. Fit testing is required for all tight-fitting 

respirators, such as CBRN SCBAs, PAPRs equipped with a tight-fitting full facepiece, and APRs. 

Another way to evaluate respirator fit is by checking the facepiece seal of a CBRN respirator. OSHA 

requires the positive or negative user seal check test be successfully completed in the field after each 

donning of a CBRN tight-fitting respirator. 

Additional information and details on respirator fit testing are provided in Chapter 6. 

Procedures for Proper Use of CBRN Respirators in Routine and Reasonable 

Foreseeable Emergency Situations 

Procedures are required to instruct the worker on the proper use of CBRN respirators in routine and 

reasonably foreseeable emergency situations. These procedures must ensure the worker knows how to 

use the CBRN respirator properly to obtain the necessary level of protection. A clean and unobstructed 

respirator-sealing surface on the wearer’s face is pivotal in ensuring the respirator seals properly. CBRN 

respirator use procedures should forbid facial hair and the use of eyeglass temple bars or straps that 

interfere with the respirator-sealing surface. Controlling facial hair/beards has presented ongoing 

respirator program issues for decades. A personnel policy that clearly states that facial hair is not 

permitted for specific jobs that require the use of CBRN respirators with tight-fitting facepieces is the 

best way to address this issue. Some accommodation can be made for facial hair by using a PAPR 

equipped with a hood, but this respirator cannot be used in an immediately dangerous to life or health 

(IDLH) environment or when concentrations exceed 1000 times the OSHA permissible exposure limit. 

When other personal protective equipment is provided, the employer shall ensure that it does not 

interfere with the seal of the facepiece. If the user requires corrective lenses, specific manufacturer 

spectacle insert kits with the appropriate prescription lenses shall be provided. Alternatively, contact 

lenses can be worn. 

Another required procedure should lay out an ongoing activity to determine the effectiveness of CBRN 

respirators in use. This activity requires an evaluation of how the respirators are used and maintained 

in the field, as well as how the worker behaves when using the respirator. When respirator performance 

or use problems are observed in the field, the employer must make sure the worker leaves the 

respirator use area before removing the respirator to address the issue. Any issues identified should be 

documented and corrected. OSHA requires a separate procedure for entry into IDLH atmospheres that 

lists the specific requirements and details to be followed. This IDLH procedure should address: 

A dedicated outside standby person 

Communication between entrant and outside standby 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 95 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

Appropriate training and equipment (SCBA or positive pressure airline respirator with five minute 

escape cylinder) for the entrant(s) and outside standby to provide effective emergency rescue 

Communication with the employer by the outside standby before undertaking a rescue 

Appropriate employer action when informed of a rescue being initiated 

Appropriate entrant retrieval equipment, where appropriate 

Equivalent means for rescue where retrieval equipment is not required 

The IDLH environment for structural firefighting requires at least two firefighters located on the outside 

of the IDLH environment when two or more firefighters enter the IDLH environment. All firefighters 

involved in structural firefighting must be equipped with SCBAs. Checklists that summarize the 

requirements of these procedures make good training aids and improve the understanding, 

performance, and compliance. 

Procedures and Schedules for Cleaning, Disinfecting, Storing, Inspecting, 

Repairing, Discarding, and Otherwise Maintaining CBRN Respirators 

Maintenance and care procedures should address the how and when of these processes to ensure CBRN 

respirators function properly after routine use or storage. CBRN respirators that come in direct contact 

with a CBRN agent are typically bagged, isolated, and decontaminated or disposed of on a case- by-case 

basis. Procedures that follow the manufacturer’s directions for routine cleaning, disinfecting, and repair 

of respirators should be incorporated into respirator maintenance procedures and implemented. 

Appendix B-2 of OSHA 29 CFR 1910.134 provides an alternate method for cleaning and disinfecting of 

respirators. After cleaning and disinfection, the respirators should be inspected, tested, and repaired 

where necessary to ensure each respirator is functional and ready to use before it is returned to service. 

Respirators that are found to be defective and cannot be repaired should be discarded. Properly trained 

individuals following the manufacturer’s directions and using NIOSH-approved parts designed for that 

respirator must perform any respirator repairs. Reducing and emission valves, regulators, and alarms 

must be adjusted or repaired only by the manufacturer or a technician trained by the manufacturer. 

Respirator components must not be replaced with others that are not listed on the NIOSH approval 

label, even if they appear to be similar. 

Canisters of CBRN respirators are interoperable among NIOSH-approved CBRN APRs. This is due in part 

to the adoption of facepiece mechanical connector design specifications and standardized threads which 

match canister specifications on all NIOSH-approved CBRN APRs. These interoperability requirements do 

not apply to NIOSH-approved industrial gas masks. Interoperable use of CBRN canisters is only 

acceptable when authorized by OSHA during an emergency, provided that the NIOSH-approved CBRN 

APR canister selected provides protection at the same level (e.g., CAP 1 or Cap 2, etc.) as the canister 

specified on the NIOSH CBRN approval label. 

Use of components not listed on the full NIOSH approval label for the CBRN respirator 

constitutes configurations not included in the NIOSH CBRN approval and may result in serious 

injury and/or death of the wearer. 

Respirators must be stored to protect them from damage, contamination, dust, sunlight, extreme 

temperatures, excessive moisture, and damaging chemicals. They must also be packed or stored to 

prevent deformation of the facepiece and exhalation valve. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 96 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

CBRN respirators and cartridges must be kept in their original packages per the manufacturer’s 

instructions. CBRN respirators maintained for emergency response purposes must be inspected at least 

monthly and immediately prior to use. Emergency escape respirators must be inspected before being 

taken into the workplace for use. 

Procedures to Ensure Adequate Air Quality, Quantity, and Flow of Breathing Air 

for Atmosphere-Supplying CBRN Respirators 

Breathing air for CBRN atmosphere-supplying respirators is required to meet purity and quality levels for 

content, and not exceed certain contaminant levels and moisture requirements. OSHA requires that 

CBRN respirator breathing air meet the requirements for Grade D breathing air described in ANSI G-7.1-

2011 [ANSI/CGA 2001]. 

Cylinders used to supply breathing air to respirators must be tested and maintained as prescribed by the 

Department of Transportation [Transporation specifications, 2006]. When air is purchased in cylinders, a 

certificate of analysis must be obtained from the supplier to assure that the breathing air meets the 

Grade D specification. The moisture content in the cylinders must not exceed a dew point of -50°F (-

45.6°C) at one atmosphere pressure. If a compressor is used to supply breathing air for SCBA tank filling 

or for airline respirators, the compressor should be located so that contaminated air does not enter into 

the air supply system. Moisture content should be controlled so that the dew point at one atmosphere 

pressure is 10°F below ambient temperature. The compressor should also be equipped with suitable inline air-purifying sorbent beds and filters to further ensure breathing air quality. Carbon monoxide 

breathing air levels must not exceed 10 parts per million (ppm) for non oil-lubricated compressors. Oillubricated compressors must be equipped with a high-temperature or carbon monoxide monitor or both 

to monitor for carbon monoxide. If only a high-temperature alarm is used, the breathing air must be 

monitored at intervals to prevent carbon monoxide levels in the breathing air from exceeding 10 

ppm. Breathing air hose couplings shall be unique to prevent the connection to non-respirable air or 

other gas systems. Breathing air cylinders shall be marked in accordance with the NIOSH certification 

standard, 42CFR Part 84. 

NFPA 1989, “Standard on Breathing Air Quality for Emergency Service Respiratory Protection,”[NFPA 

2013e] requires quarterly air sampling from breathing air systems to confirm compliance with 

requirements for oxygen, carbon monoxide, carbon dioxide, condensed oil and particulate content, 

water content, non-methane volatile organic compounds, odor, and nitrogen content. Commercial 

contractors provide this quarterly sampling service utilizing a sampling system that is returned for 

analysis after the sample is collected. Sample results from some services are available on the web within 

a short period of time. 

Procedures for Training 

OSHA requires that the employer provide effective training to employees who must wear CBRN 

respirators. The training must be comprehensive, understandable, and recur annually or more often if 

necessary. For the training to be judged successful, the employees must be able demonstrate 

knowledge and understanding in the following areas: 

Why the CBRN respirator is necessary 

How improper fit, usage, and maintenance can compromise the protective effect of this 

respirator 

What the limitations and capabilities of this respirator are 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 97 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

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

respirator malfunctions 

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

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

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

respirator 

The general requirements of 1910.134 

NFPA provides specific firefighter training requirements for SCBAs in NFPA 1404, “Standard for Fire 

Service Respiratory Protection Training”[NFPA 2013c]. Additional information on employee training can 

be found in Chapter 9. 

Procedures for Regularly Evaluating Effectiveness of the Program 

Regular evaluations of the workplace are required to ensure that the written CBRN respiratory 

protection program is being properly implemented and workers are using the respirator properly. 

Consulting with employees who use the respirators is necessary to identify any concerns they have with 

the program. This evaluation should review, at a minimum, respirator fit, appropriate respirator 

selection for the hazards to which the employee is exposed, proper respirator use, and proper 

maintenance and storage. A written report should be prepared summarizing the findings and 

recommended corrective actions. A follow up report closing out the corrective actions should also be 

prepared. As a rule of thumb, these evaluations should be done at least annually or more frequently if 

significant issues are identified. 

Recordkeeping 

OSHA requires the employer to establish and retain written information regarding medical evaluations, 

fit testing, and the respiratory protection program. Medical records must be preserved and maintained 

for at least the duration of employment plus thirty years, with several exceptions noted in the section 

addressing access to employee exposure and medical records, 29 CFR 1910.1020 [Access to employee 

exposure, 2006]. Qualitative and quantitative fit test results must be kept until the next fit test is 

administered. A written copy of the respiratory protection program must also be retained. 

Summary 

A major task of the emergency services respiratory protection program manager is the preparation, 

implementation, and revision of the elements of the respiratory protection program and the various 

standard operating procedures identified in the respiratory protection program. Each of the nine OSHA 

respiratory protection program elements can require one or more SOPs. The addition of CBRN 

respiratory protection requires the inclusion of additional information in the SOPs and in some cases the 

creation of additional SOPs. Appendix C contains two respirator program examples from a fire and police 

organization for review: Sonoma County Fire and Emergency Services Department, Respiratory 

Protection Program, Revised 2/20/11; [Sonoma County Fire and Emergency Services Department 2011] 

and the Fort Collins Police Services, Office of Chief of Police, Directive No. D-6, Respiratory Protection 

Policy, March 24, 2009 [Fort Collins Police Services 2009]. These examples are provided to illustrate how 

different organizations address SOPs and a respiratory protection program. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 98 
 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

References 

Access to employee exposure and medical records. 29 CFR 1910.1020 (2006). 

ANSI [1969]. ANSI Z88.2 Practices for respiratory protection. Washington, DC: American National Standards 

Institute. 

ANSI [2006]. ANSI Z88.6-2006: Practices for respiratory protection – physical qualifications for respirator use. 

Washington, DC: American National Standards Institute. 

ANSI/CGA [2001]. ANSI/CGA G-7.1-1997: Commodity specification for air. Washington, DC: American National 

Standards Institute. 

ASA [1938]. ASA Z2: American standard safety code for the protection of heads, eyes, and respiratory organs. 

Washington, DC: American National Standards Institute. 

ASA [1959]. ASA Z2.1 American standard safety code for head, eye, and respiratory protection. New York, NY: 

American Standards Association Inc. 

Cloonan TK [2011]. CBRN respiratory protection program design. Poster presented at the NPPTL 

Stakeholders Meeting, Pittsburgh, PA, March 29. 

Cummings MC, Mcgarvey DC, Vinch PM [2006]. Homeland security risk assessment. Methods, techniques, 

and tools. Vol II. Arlington, VA: Homeland Security Institute. 

EPA [2007]. Guidance for preparing standard operating procedures (SOPs). Washington, DC: US 

Environmental Protection Agency, Office of Environmental Information, https://nepis.epa.gov/Exe/ 

FEMA [1999]. Guide to developing effective standard operating procedures for fire and EMS departments. 

Emmitsburg, MD: US Fire Administration, Federal Emergency Management Agency, 

https://www.usfa.fema.gov/downloads/pdf/publications/fa-197-508.pdf 

Fort Collins Police Services [2009]. Respiratory protection policy. Directive No. D-6. Fort Collins, CO: Fort 

Collins Police Services. 

NFPA [2013a]. NFPA 472: Standard for competence of responders to hazardous materials/weapons of mass 

destruction incidents. Quincy, MA: National Fire Protection Association. 

NFPA [2013b]. NFPA 473: Standard for competence of EMS personnel responding to hazardous 

materials/weapons of mass destruction incidents. Quincy, MA: National Fire Protection Association. 

NFPA [2013c]. NFPA 1404: Standard for fire service respiratory protection training. Quincy, MA: National Fire 

Protection Association. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 99 
 

 

 

 

 

 

 

 

 

CHAPTER 5 

CBRN RESPIRATORY PROTECTION PROGRAM REQUIREMENTS 

NFPA [2013d]. NFPA 1582: Standard on competence occupational medical program for fire departments. 

Quincy, MA: National Fire Protection Association. 

NFPA [2013e]. NFPA 1989: Standard on breathing air quality for emergency services respiratory protection. 

Quincy, MA: National Fire Protection Association. 

OSHA [1971]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

OSHA [1990]. 29 CFR 1910.120 Hazardous waste operations and emergency response. Washington, DC: U.S. 

Department of Labor, Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9765. 

OSHA [1998]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

OSHA [1999]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

OSHA [2006]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

SAFECOM [2006]. Writing guide for standard operating procedures. Washington, DC: Department of 

Homeland Security, Office for Interoperability and Compatibility, SAFECOM, 

https://www.dhs.gov/sites/default/files/publications/Writing%20Guide%20for%20Standard%20Operating%2 

0Procedures.pdf 

Sonoma County Fire and Emergency Services Department [2011]. Procedure manual, safety program, 

respiratory protection program. Santa Rosa, CA: Sonoma County Fire and Emergency Services Department, 

http://www.sonoma-county.org/fire/pdf/fire/sop/2_8_2_respitory_protection_program.pdf 

Transportation specifications for shipping containers. 49 C.F.R., Part 173 and Part 178 (2006). 

Worker protection. 40 CFR 311. (2011). 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 100 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

CHAPTER 6 – 

CBRN RESPIRATOR FIT TESTING METHODS 

Author: James S. Johnson 

Introduction 

Respirator fit is a critical component in providing adequate chemical, biological, radiological, and nuclear 

(CBRN) respiratory protection. A variety of techniques have been used since 1934 [USBM 1934] to 

evaluate respirator fit. In 1971, the Occupational Safety and Health Administration (OSHA) adopted 

American National Standards Institute (ANSI) Z88.2-1969 [ANSI 1969] as their respiratory protection 

regulations, and 29 Code of Federal Regulations (CFR) 1910.134 “Respiratory Protection”[OSHA 1971] 

with essentially no changes made related to respirator fit testing. In the revision of ANSI Z88.2 in 1980 

[ANSI 1980], the terms qualitative and quantitative fitting test were introduced. A qualitative fit test is a 

pass/fail test method that relies on the subject’s sensory response to detect a challenge agent in order to 

assess the adequacy of respirator fit. A quantitative fit test uses an instrument to assess (quantify) the 

amount of face seal leakage into the respirator in order to assess adequacy of its fit. Each fit test method 

has advantages and disadvantages. Qualitative fit tests do not require expensive equipment, but the test 

subject can influence the results. Quantitative fit tests require expensive equipment, but the results are 

independent of any test subject influence. These two general types of respirator fit tests provide the 

basis for measuring respirator fit. 

Respirator Fit Testing 

The primary purpose of respirator fit testing is to choose a specific make, model, style, and size of a tightfitting CBRN full facepiece respirator that properly fits the wearer and provides protection. Currently, 

National Institute for Occupational Safety and Health (NIOSH)-approved CBRN respirators that require fit 

testing only use tight-fitting full facepieces. OSHA requires both positive and negative pressure tightfitting full facepiece respirators be fit tested. To fit test positive pressure tight-fitting full facepiece 

respirators, a negative pressure full facepiece respirator that matches the positive pressure full facepiece 

respirator can be substituted. Adaptors are also available from respirator manufacturers to permit a 

negative pressure fit test using the positive pressure tight-fitting facepiece. 

The fit test methods chosen for negative pressure full facepiece respirators must be able to detect a leak 

(penetration) into the respirator of at least 0.2 percent to determine if the respirator is providing the 

pass/fail required fit factor (FF) of 500. A measured leak of 0.2 percent results in a fit factor of 500 (FF = 1 

÷ % leakage = 1 ÷ 0.002 = 500). A fit factor of 500 divided by a required safety factor of 10 results in an 

assigned protection factor of 50. OSHA requires that fit testing of negative pressure full facepiece 

respirators be carried out using quantitative fit test procedures when a protection factor of 50 is 

required. This is because existing qualitative fit test procedures were developed to screen for a fit factor 

of 100. That is, they can detect a leak into the respirator of one percent or greater. 

For positive pressure tight-fitting full facepiece respirators, OSHA regulations and National Fire 

Protection Association (NFPA) standards permit the use of a qualitative or quantitative fit test. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 101 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

This means powered air-purifying respirators (PAPRs) equipped with tight-fitting full facepieces and 

CBRN self-contained breathing apparatus (SCBAs) can be fit tested using a qualitative or quantitative To 

achieve the required level of respiratory protection for CBRN agents, some respirator manufacturers 

specify a fit factor higher than 500 for their full facepiece respirators in the user instructions. 

Manufacturer-specified fit factors currently range from 500 to 2500 and must be identified by the 

respirator program manager and used by the RFT operator to determine the correct pass/fail value for 

that specific respirator. As noted previously, OSHA requires the minimum pass level of 500 for 

quantitative fit tests for tight-fitting full facepiece respirators, but would allow a manufacturer’s higher 

pass level to be used. Because of the positive pressure maintained inside the full facepiece for these 

classes of respirators, a qualitative fit test is permitted. The general purpose for these tests on positive 

pressure respirators is to identify significant facepiece-to-face leaks. The quantitative fit test is only 

required when the fit test is used for negative pressure CBRN air-purifying respirator (APR) facepieces. 

Respirator fit testing provides the opportunity for hands-on training of the respirator wearer. This 

training is complementary to the normal classroom or computer-based training typically provided to 

respirator users. In either a qualitative or quantitative fit test, a respirator fit test (RFT) operator 

observes the wearer as he or she puts on the respirator, adjusts the strap tightness, positions the 

respirator on the face and the straps on the head, and carries out a positive and/or negative user seal 

check. During the mask donning and checking process, the RFT operator can provide hands-on 

instruction, as needed, to ensure the mask is worn properly and the user seal checks are conducted 

correctly. The RFT operator can also demonstrate the test results with (and thus the danger of) improper 

donning. 

To achieve the required level of respiratory protection for CBRN agents, some respirator manufacturers 

specify a fit factor higher than 500 for their full facepiece respirators in the user instructions. 

Manufacturer-specified fit factors currently range from 500 to 2500 and must be identified by the 

respirator program manager and used by the RFT operator to determine the correct pass/fail value for 

that specific respirator. As noted previously, OSHA requires the minimum pass level of 500 for 

quantitative fit tests for tight-fitting full facepiece respirators, but would allow a manufacturer’s higher 

pass level to be used. 

Fit Test Methods 

The OSHA regulation, 29 CFR1910.134, recognizes the following qualitative fit test (QLFT) and 

quantitative fit test (QNFT) methods. 

Qualitative fit test methods: 

Isoamyl acetate 

Saccharin 

Bitrex (denatonium benzoate) 

Irritant smoke (stannic chloride) 

Quantitative fit test methods: 

Generated aerosol 

Ambient aerosol 

Controlled negative pressure 

The general QLFT and QNFT requirements and instructions for both the person being fit tested and the 

person conducting the fit test are provided in the mandatory Appendix A [OSHA 1998] of 29 CFR 

1910.134. This standardizes the methods used and provides more consistent fit test results. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 102 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

Before being fit tested, the test subject must first pass a user seal check. A general overview of each test 

is provided below with specific procedural details, where appropriate. 

Qualitative Fit Test Methods 

Isoamyl Acetate Method 

Isoamyl acetate is an organic liquid that makes a very good qualitative test agent because it has a 

distinctive banana-like odor at low concentrations and is easily adsorbed by air-purifying organic vapor 

cartridges. The steps in an isoamyl acetate test are as follows: 

1. RFT operator verifies that the test subject can detect isoamyl acetate at a predetermined low 

concentration. 

2. Test subject puts on the CBRN full facepiece respirator equipped with organic vapor cartridges in a 

room separated from the test chamber and performs a user seal check. 

3. Test subject enters the test chamber, exposes a known volume of isoamyl acetate in the test 

chamber, and waits two minutes for the test atmosphere to stabilize. 

4. Test subject begins the prescribed fit test exercises. If at any time the test subject detects a bananalike odor, the test is failed and the test subject exits the test chamber. If the test subject completes 

all of the required exercises to pass the test, the respirator seal is broken before exiting the chamber 

to demonstrate the efficiency of the respirator. 

Saccharin Method 

Saccharin is an artificial sweetener that can be aerosolized easily using a nebulizer to make a small 

aerosol test atmosphere. The steps in a saccharin test are as follows: 

1. RFT operator verifies the sensitivity of the test subject to the taste of saccharin, via a small portable 

enclosure placed over the test subject’s head with a 3⁄4-inch hole at nose level. RFT operator fills a 

specified commercially available nebulizer with a specified solution of saccharin and distilled water, 

inserts the nebulizer outlet nozzle into the 3⁄4-inch hole, and squeezes it ten times. If a sweet taste is 

detected, the test subject is ready to proceed with the test. Two additional 10-squeeze exposures can 

be administered to determine if the test subject can taste the saccharin. RFT operator notes the 

number of 10-squeeze exposures and uses this information for the respirator test. If the subject tastes 

nothing after three tries, the test may not be performed on that subject. 

2. The qualified test subject dons the CBRN full facepiece respirator equipped with the appropriate filter, 

performs a user seal check, and places the enclosure over the respirator and his/her head. 

3. RFT operator inserts the nebulizer nozzle into the 3⁄4-inch hole and completes one, two, or three tensqueeze exposures, based on the taste test. 

4. Test subject carries out the required fit test exercises and the test atmosphere is replenished every 30 

seconds with one half of the original number of nebulizer squeezes used (5, 10, or 15). If the taste of 

saccharin is detected at any time during the required exercises, the fit is deemed unsatisfactory and 

the test is failed. If the taste of saccharin is not detected throughout all of the required exercises, the 

test is passed. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 103 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

Bitrex (Denatonium Benzoate) Method 

Bitrex is bitter-tasting chemical that is widely used as a taste aversion agent in household liquids. It can 

be aerosolized easily using a nebulizer to make a small aerosol test atmosphere. The steps in a Bitrex 

test are as follows: 

1. RFT operator verifies the sensitivity of the test subject to the taste of Bitrex via a small portable 

enclosure placed over the test subject’s head with a 3⁄4-inch hole at nose level. RFT operator fills a 

specified commercially available nebulizer with a specified solution of Bitrex and five percent salt 

water. RFT operator inserts the nebulizer outlet nozzle into the 3⁄4-inch hole and squeezes it 10 times. 

If a bitter taste is detected, the test subject is ready to proceed with the test. Two additional 10-

squeeze exposures can be administered to determine if the test subject can taste the Bitrex. The RFT 

operator notes the number of 10-squeeze exposures and uses this information for the respirator test. 

If the subject tastes nothing after three tries, the test may not be performed on that subject. 

2. The qualified test subject dons the CBRN full facepiece respirator, equipped with the appropriate 

filters, performs a user seal check, and places the enclosure over the respirator and his/her head. 

3. RFT operator inserts the nebulizer nozzle into the 3⁄4-inch hole and completes one, two, or three tensqueeze exposures, based on the taste test. 

4. Test subject carries out the required fit test exercises and the test atmosphere is replenished every 30 

seconds with one half of the original number of nebulizer squeezes used (5, 10, or 15). If the taste of 

Bitrex is detected at any time during the required exercises, the fit is deemed unsatisfactory and the 

test is failed. If the taste of Bitrex is not detected throughout all of the required exercises, the test is 

passed. 

Irritant Smoke (Stannic Chloride) Methoda 

Irritant smoke tubes contain a mixture of vermiculite and stannic chloride. When the ends of the tube 

are removed and a squeeze bulb is attached to one end, the ambient humidity of the air forced through 

the tube produces a white smoke consisting of hydrogen chloride and tin compounds. Exposure to this 

test agent causes an immediate involuntary cough in the test subject. The test must be performed in an 

area with adequate ventilation to prevent test agent exposure to the RFT operator. The CBRN full 

facepiece respirator must be equipped with P100 filters. The steps in an irritant smoke test are as 

follows: 

1. RFT operator uses a weak concentration of the irritant smoke to confirm the test subject’s response. 

2. Test subject dons the respirator and performs a user seal check to confirm the seal integrity. 

3. RFT operator directs a stream of irritant smoke toward the faceseal area and moves the smoke stream 

around the perimeter of the mask. 

4. Test subject carries out the required fit test exercises and if any irritant smoke is detected the test is 

failed. If no irritant smoke is detected throughout the required fit test exercises and a final sensitivity 

response is confirmed, the fit test is passed. 

a NIOSH does not recommend the use of this test method because of the health risk associated with the exposure 

to irritant smoke, hydrochloric acid [NIOSH 2005]. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 104 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

Quantitative Fit Test Methods 

Generated Aerosol Method 

The generated aerosol QNFT method uses a generated aerosol, such as corn oil, as the test agent in an 

enclosed space. The steps in a generated aerosol test are as follows: 

1. Test subject dons the probed respirator equipped with P100 filters and related sampling equipment if 

required. 

2. Test subject performs a user seal check before entering the enclosure. 

3. Once inside the enclosure, test subject connects the sampling hose to the aerosol monitor sampling 

port. 

4. Test subject performs the required set of exercises and the interior of the respirator is monitored for 

aerosol leakage with an aerosol monitor, such as a forward light scattering photometer, during each 

exercise. 

5. RFT operator compares the inside aerosol concentration to the outside aerosol concentration for each 

exercise and averages them to determine the average leak rate (penetration) and fit factor for the 

respirator. 

Respirators used in quantitative fit testing are modified by adding a sampling probe centered between 

the nose and the upper lip. This allows a sample to be collected from the breathing zone inside the 

facepiece/nosecup of the respirator. Probed respirators are available from individual respirator 

manufacturers to use for quantitative fit testing. Sampling probe kits are also available to permanently 

or temporarily modify the respirator to install a sampling probe. 

Ambient Aerosol Method 

The ambient aerosol QNFT method uses ambient aerosol as the test agent. In some cases, the ambient 

aerosol concentration has to be supplemented to provide an adequate challenge concentration to assure 

valid measurements. Sometimes this can be accomplished by simply burning a candle in the room in 

which the fit test is performed. Special aerosol generators are also available for this purpose. The steps in 

an ambient aerosol test are as follows: 

1. Test subject dons the probed respirator equipped with P100 filters and performs a user seal check. 

2. Test subject takes the attached sampling hose, connects it to the ambient aerosol monitor 

instrument, and carries out the required set of exercises. 

3. RFT operator monitors the interior of the respirator for aerosol leakage with an aerosol monitor, such 

as a condensation nuclei counter (e.g., TSI Portacount). 

4. RFT operator compares the inside concentration to the outside concentration for each exercise and 

averages them to determine the average leak rate (penetration) and fit factor for the respirator. 

These calculations can be automated using a computer and software provided by the equipment 

manufacturer. 

Controlled Negative Pressure Method 

The controlled negative pressure QNFT method uses air molecules as the test agent. An instrument is 

used to generate a negative pressure inside the facepiece of the respirator, while the subject holds 

his/her breath to measure the resulting volumetric air leak rate. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 105 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

The negative pressure generated in the respirator facepiece corresponds to a specific predetermined 

inspiratory flow rate. To perform this test, the respirator must be modified with the appropriate 

controlled negative pressure test adaptors before the test subject dons it. 

The steps in a controlled negative pressure test are as follows: 

1. Test subject dons the modified respirator. 

2. Test subject completes a required set of exercises, stopping at the completion of each exercise to 

permit the controlled negative pressure measurement device to determine the leak rate. Before the 

measurement is initiated, the test subject takes a breath and holds it. The controlled negative 

pressure monitor is started, produces a negative pressure in the respirator, and measures the flow 

of air exhausted to maintain a constant pressure during the test period. 

1. RFT operator measures the exhausted air after each exercise and uses the measurement to calculate 

the leak rate (penetration) and fit factor for the respirator (e.g., OHD FitTester 3000). 

Fit Test Exercises 

OSHA requires the test subjects to perform the following exercises in the various test environments. 

1. Normal breathing. In a normal standing position, without talking, the subject must breathe normally. 

2. Deep breathing. In a normal standing position, the subject must breathe slowly and deeply, taking 

caution so as not to hyperventilate. 

3. Turning head side to side. Standing in place, the subject must slowly turn his/her head from side to 

side between the extreme positions on each side. The head must be held at each extreme 

momentarily, so the subject can inhale at each side. 

4. Moving head up and down. Standing in place, the subject must slowly move his/her head up and 

down. The subject must inhale in the up position (i.e., when looking toward the ceiling). 

5. Talking. The subject must talk slowly and loud enough 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. 

6. Grimace. The test subject must grimace by smiling and frowning. 

7. Bending over or jogging in place. The test subject must bend at the waist as if he/she were touching 

his/her toes. 

8. Normal Breathing. Same as exercise number 1. 

In 29 CFR 1910.134, Appendix A, OSHA provides a modified set of exercises for the controlled negative 

pressure method, with a set of five exercises that include respirator redonning. The three quantitative fit 

test methods previously described require each exercise to be carried out for one minute, except the 

grimace exercise that must be performed for 15 seconds. The grimace exercise is not required for any of 

the qualitative fit test methods and the results from this test are not used in calculating the overall 

respirator fit factor for the quantitative fit tests. One can expect the results from the individual fit test 

exercises to vary, but it is the overall fit factor of the respirator that is used to determine pass or fail of a 

quantitative respirator fit test. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 106 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

User Seal Check 

An adequate facepiece seal is necessary for a CBRN respirator to provide the proper level of protection. 

The positive or negative user seal check test must be completed successfully as part of a qualitative or 

quantitative fit test and in the field after each donning of a CBRN tight-fitting respirator. To carry out a 

positive pressure user seal check, the wearer closes off the exhalation valve or the SCBA mask mounted 

regulator opening on the respirator with the palm of the hand and exhales gently into the facepiece. The 

fit is considered satisfactory if a slight positive pressure builds up inside the facepiece without any 

evidence of outward leakage of air at the seal. To carry out a negative pressure user seal check, the 

wearer closes of the inlet opening of the cartridges, canister, or SCBA mask mounted regulator opening 

with the palm of the hand and inhales gently so that the facepiece collapses slightly, and holds his/her 

breath for 10 seconds. If the facepiece remains in its slightly collapsed condition and no inward leakage 

of air is detected, the tightness of the respirator is considered satisfactory. If the palm of the hand 

cannot effectively cover the canister or mask mounted regulator opening, a thin latex or nitrile glove can 

be used to cover it. When performing a user seal check without the SCBA regulator in place, only the air 

tightness of the sealing surface of the mask to face can be evaluated. When carrying out the user seal 

check, the worker should be trained to examine the respirator for any defective parts (e.g., facepiece, 

head straps, valves, connecting tube, and cartridges or canisters) that are not functioning properly. If any 

problems are identified, the respirator should be repaired or replaced. 

See Chapter 5 for specific details on implementing qualitative and/or quantitative fit testing as part of 

the respirator program. ANSI/AIHA Z88.10-2010, “Respirator Fit Testing Methods,” provides additional 

help on how to conduct fit testing of tight-fitting respirators [AIHA/ANSI 2010]. 

Summary 

Respirator fit is a critical component for providing adequate CBRN respiratory protection and a major 

part of any respirator program. The primary purpose of respirator fit testing is to choose a specific make, 

model, style, and size of a tight-fitting CBRN full facepiece respirator that properly fits the wearer. 

Qualitative and quantitative fit test procedures and equipment, as well as specific test exercises, should 

be followed to determine if a respirator fits properly. Positive and negative pressure user seal checks are 

also available to confirm the respirator is being worn correctly. Initial and annual respirator fit testing 

and use of a user seal check as part of each donning are major components in providing respiratory 

protection to workers wearing CBRN respirators. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 107 
 

 

 

 

 

CHAPTER 6 

CBRN RESPIRATOR FIT TESTING METHODS 

References 

AIHA/ANSI [2010]. ANSI/AIHA Z88.10-2010 Respirator Fit Testing Methods. Washington D.C. American 

Industrial Hygiene Association: American National Standards Institute, Inc. 

ANSI [1969]. ANSI Z88.2-1969 American National Standard Practices for Respiratory Protection. Washington, 

DC: American National Standards Institute. 

ANSI [1980]. ANSI Z88.2-1980 American National Standard Practices for Respiratory Protection. Washington, 

DC: American National Standards Institute. 

NIOSH [2005]. NIOSH Respirator Selection Logic. Cincinnati, OH: U.S. Department of Health and Human 

Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/docs/2005-100/ 

OSHA [1971]. 29 CFR 1910.134 Respiratory protection. Washington, DC: U.S. Department of Labor, 

Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=12716. 

OSHA [1998]. 29 CFR 1910.134 Respiratory Protection, Appendix A. Washington, DC: U.S. Department of 

Labor, Occupational Safety and Health Administration, 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9780 

OSHA [2011]. Interpretation of the fit-testing requirements for CBRN respirators. Washington, D.C. 

Occupational Safety and Health Administration. 

USBM [1934]. Schedule 21, procedure for testing filter-type dust, fume, and mist respirators for 

permissibility. Washington, DC: U.S. Department of Interior, United States Bureau of Mines. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 108 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

CHAPTER 7 – 

CBRN EQUIPMENT AND THE WEARER 

Author: Arthur T. Johnson 

Introduction 

Appropriate equipment and effective chemical, biological, radiological, and nuclear (CBRN) respiratory 

protection programs are necessary to provide and maintain the protection needed to survive emergency 

disasters when toxic materials are involved. CBRN respirators and protective clothing are designed, 

assembled, and tested to ensure they are capable of the level of protection that first responders and 

ancillary personnel need to respond appropriately to emergencies and to do so without damage to 

themselves [Johnston et al. 2001]. However, the protection afforded by the equipment comes with a 

price: For each additional piece of protective equipment worn to separate the wearer from the hazard, 

there is a performance penalty. Once adequate protection has been afforded, wearers must cope with 

the burdens of protective equipment that affect their abilities to perform assigned tasks. Understanding 

of normal physiological adjustments to exertion and the alterations imposed by protective equipment is 

of the utmost importance. A solid understanding of how equipment affects performance will help: 

 The individual responder form more realistic self-expectations in an emergency 

 The supervisor or crew chief form realistic expectations of his/her first and second responders 

 Emergency management personnel plan realistically for means to deal with emergencies 

 Medical personnel (first receivers) recognize the challenges they face when dealing with the 

aftermath of a catastrophe 

 Program managers who procure personal protective equipment make informed choices that 

minimize detriment to performance 

This chapter focuses on the wearers of protective equipment and how their abilities are affected by the 

equipment that keeps them alive [Johnson and Dooly 1995a,b]. 

At the end of this chapter is a summary of physiological adjustments to exercise. This summary explains 

what goes on inside the body when working, and aids understanding of the effects of respirators and 

other personal protective equipment (PPE) on responders in emergency situations. 

The Nature of the Threat to Health 

Contaminants of many kinds may be present at the site of an emergency. As the description “chemical, 

radiological, biological, and nuclear” suggests, contaminants may be any of these types, each with its 

own particular threat to the health of the responder. This section explains possible health effects of 

some contaminants likely to be encountered by emergency responders. It is important for wearers of 

CBRN PPE to understand the threats they face and the repercussions of improper protection. Respirator 

filter cartridges are constructed to remove each of these airborne contaminants from the air that is 

breathed. 

Gases/Vapors [Johnson 1997, 2007, 2011] 

Many of the gases and vapors produced in a fire are classified as asphyxiants or irritants [Harrison and 

Elkabir 2006]. The most common are carbon monoxide and hydrogen cyanide. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 109 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Carbon monoxide, like oxygen, links to hemoglobin in the red blood cells, but unlike oxygen, does not 

release easily. Carbon monoxide, a product of incomplete combustion of hydrocarbons, is about 200 

times more tightly bound to hemoglobin than is oxygen. If enough hemoglobin sites for oxygen are filled 

with carbon monoxide, body cells can no longer be supplied with sufficient oxygen, and death is 

imminent. If exposure to carbon monoxide is nonlethal it can still lead to serious complications even at 

low carbon monoxide concentrations. The victim must either be placed in hyperbaric oxygen chamber 

for a long time to force the carbon monoxide to leave the hemoglobin sites, or be given supplemental 

oxygen through some other means. Even then, some central nervous system damage may persist. 

Hydrogen cyanide is also dangerous [Caretti et al. 2007; Harrison and Elkabir 2006]. Cyanide irreversibly 

binds to an enzyme in cells critical for the metabolism of glucose to form energy. As a result, cells cannot 

use oxygen from the blood and the person can die if enough hydrogen cyanide is inhaled. Humans, as 

well as other animals, have a small tolerance to cyanide, but the concentration of cyanide in a fire can 

cause death [Jones et al. 1987]. 

Irritants may be either inorganic or organic, and are usually produced when organic materials in 

furniture, wallboard, resins, adhesives, paint, pesticides, petroleum, plastics, solvents, and other 

construction materials are burned [Harrison and Elkabir 2006; Sumi and Tsuchiya 1973]. This class of 

contaminants causes immediate irritation of the respiratory tract. Those that are water soluble irritate 

the upper airways, whereas insoluble gases irritate the lower airways. Depending on the nature of the 

gas or vapor, irritation may range from mild to severe. The bronchial airways may constrict in response 

to serious irritation, cutting off air to the lungs. 

Rescue workers and others exposed to the dusts, gases, and fumes at the World Trade Center site in 

New York were tested and some were found to lack the ability to detect odors and irritants years after 

they left the area [LaTourrette et al. 2003; NIOSH 2017]. The insidious property of irritating gases is a 

major reason why implementing change schedules, rather than relying on responders’ sensory warnings, 

is necessary in emergency response situations where responders use air-purifying respirators: 

Responders may not realize they are being affected by the irritants. 

Chemical agents may also be present at the site of a terrorist attack. There are a number of possible 

effects with gases or vapors, including neuromuscular (e.g., sarin), irritating (e.g., tear gas, chlorine), 

asphyxiants (e.g., cyanide), and lung dysfunction (phosgene) are only some of the many possible 

examples. Sarin vapors were released in an attack in Tokyo in 1995 killing 12 people and severly injuring 

50 [Wikipedia 2012]. 

Particulates/Dusts [Johnson 1997, 2007] 

Many particulates form in events such as fires and structural collapse [Savolainen and Kirchner 1997]. 

These can range in size from nanoparticles (on the order of 10-9 meters, or 10-7 inches) to 50-100 microns 

(10-6 meters, or 10-4 inches). Larger particles require the turbulence of flame and smoke convection in 

order to remain buoyed in the atmosphere. Inhaled particles larger than 5-10 microns can be deposited 

on the walls of the respiratory system. The deposited particles are entrapped in mucous lining the 

epithelium, and cila in the epithelial cells vibrate to move the particle-laden mucous toward the throat. 

When at the throat, they can be swallowed or expelled. Smoking cigarettes can impair cilia function. 

Inhaled particles smaller in size than 10 microns are called “respirable dust.” Some of these particles 

may not impact the airway walls, and can reach the alveolar level (bottom level) of the lung. 

There they can stay and cause lung damage or be dissolved and absorbed into the body. Even chemically 

relatively inert substances such as gold or titanium dioxide can become toxic in these small sizes [Karn and 

Mathews 2007]. Some nanoparticles have been shown to be carcinogenic in animals. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 110 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

The dusts and other contaminants to which emergency workers were exposed at the World Trade Center 

(WTC) site were hazardous, but not unusual, and the concentrations of individual contaminantsin the dust 

were not unusually high [LaTourrette et al. 2003; Westfeld 2006]. Workers had prolonged exposure to a 

complex mixture and many did not wear respirators. Inhalation of toxic, highly alkaline dust (pH 10–11) is 

the probable cause of much of the upper and lower respiratory injury in rescue and recovery workers. From the 

World Trade Center Health Program at a Glance [NIOSH 2017], as of September 30, 2017, over 6700 responders 

still suffer form respiratory disorders and/or pulmonary disease. Chrysotile asbestos fibers (Figure 7-1) were 

also present in the debris from the World Trade Center collapse. Chrysotile asbestos is the most used 

form of asbestos in developed countries and its fibers appear microscopically as cylinders, with longer 

fibers being somewhat curved. Reactions in the lungs caused by asbestos fibers can result in asbestosis 

(thickening and scarring of tissue that is called fibrosis which makes breathing difficult), lung cancer or 

mesothelioma (a lethal cancer that affects the pleura (covering) of the lung) after a significant lag period 

[NIH 2011]. 

Particulates can also cause a condition known as chronic obstructive pulmonary disease (COPD), in which 

the tissue structure of the lung breaks down until it becomes difficult to exhale [NIH 2010]. COPD is the 

fourth leading cause of death in the United States [ALA 2012; NIH 2010]. 

Figure 7-1. Chrysotile bundle, World Trade Center Dust, Photo Credit: USGS: 

https://usgsprobe.cr.usgs.gov/picts2.html. 

Radiological Products 

The danger posed by radiological products depends on the type of radiation (alpha, beta, or gamma) 

emitted by the particular contaminate. Even the most energetic alpha particle frok radioactive decay can 

be stopped by the outermost layer of dead skin that covers the body. Therefore, exposure to most alpha 

particles originating outside the body is not a serious hazard. On the other hand, if alpha emitting radioactive 

materials are taken inside the body by inhalation, they can be the most damaging source of radiation 

exposure. 

The short range of the alpha particle causes the damaging effects of the radiation to be concentrated in a 

very localized area as small as few cells. Beta radiation is a light, short-range particle and is actually an ejected 

electron. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 111 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Beta radiation may travel several feet in air and is moderately penetrating and can penetrate human skin to 

the “germinal layer,” where new skin cells are produced. Like alpha-emitters, beta-emitting contaminants are 

the most harmful if deposited internally through inhalation. Gamma rays extremely high energy photons 

which can travel through most forms of matter because they have no mass. When inhaled, the ionizations 

caused by gamma-emitters take place over a greater area compares to alpha- and beta-emitters. 

Plutonium is often mentioned as a potential terrorist threat [Sutcliffe et al. 1995]. Inhaled plutonium is 

much more dangerous than is ingested plutonium because small particles of respirable size can 

penetrate the lung and enter body cells via the blood stream. A typical respirable plutonium particle that 

is three microns in size has a mass of about 1.4×10-10 grams and has a risk of increasing cancer in the 

person inhaling the particle of only 0.00017 percent [Sutcliffe et al. 1995]. 

Biological Agents [Johnson 2011] 

Almost any bacterium, virus, or prion that causes human disease can be used by terrorists to provoke 

panic in the population. Prions are abnormal proteins that are implicated in Jakob-Cruetzfeldt and 

Alzheimer’s diseases in humans [Johnson 2011]. As long as respiratory protection is used and worn 

properly, sufficient protection is available to stop the threat. 

The most notorious bacterial agent used in the recent past is anthrax, caused by a bacterium belonging to 

a class of toxin-producing microbes. Others in this class, such as salmonella, listeria, and clostridium, 

produce food poisonings of various kinds. The recent outbreaks of Ebola and Zika were caused by 

viruses. 

Anthrax is particularly dangerous because its endospore form is hardy and respirable, measuring one to 

five microns in diameter. These can cause the anthrax disease if they contact the skin or if they are 

inhaled. They are much more dangerous if inhaled. It takes an inhalation of 8,000-10,000 endospores to 

kill an average person. As few as 100 endospores may kill those most susceptible [Park 2001]. As with 

most, but not all biological agents, these bacteria need time to grow to a dangerous population size 

within the body, and therefore are not immediately lethal. 

Another biological agent of interest is ricin, a toxic material derived from castor beans. Ricin interferes 

with cellular metabolism, and can be particularly dangerous if swallowed or inhaled as a dust or mist. 

Respirator high efficiency particulate filters can easily remove these particles from the air. 

Heat 

Heat can dry and burn unprotected skin. It can also damage lung tissue to the point that oxygen and 

carbon dioxide can no longer be exchanged. 

CBRN Equipment Effects 

How CBRN Equipment Affects the Cardiovascular System [Johnson et al. 2001a] 

Data from multiple studies have shown that the use of respirators alone have no effect on heart rates of 

the wearers [Johnson et al. 2003]. From this, it appears that respirators do not impose additional stress 

on the heart. However, for respirators and protective clothing with significant weight, the additional 

weight can impose an ergonomic burden that translates into cardiac stress. This additional weight acts 

equivalently to body weight as long as it is carried close to the body. 

Each kilogram (2.2 pounds) of extra weight can be expected to reduce the work performance time by 

two and a half minutes if walking at a high speed [Johnson et al. 2006]. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 112 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

If extra weight is carried awkwardly away from the body, then the energetic penalty can be an additional 

50-60 percent of the energetic cost of carrying the load next to the body [Johnson 2007; Johnson et al. 

2006]. Extra heavy loads also add to the nonproportional energy cost of carrying them. Loads carried by 

the hands are less burdensome than loads carried on the feet. Heavy protective clothing carries with it a 

higher energy penalty than can be accounted for by its weight alone. Bulk and friction from the heavy 

clothing can also be an important factor [Johnson 2007]. 

Translating the energy requirement of wearing protective clothing and carrying (or dragging) extra 

weight into cardiac burden is not a straightforward procedure. A lot depends on whether the wearer is 

climbing up stairs or down stairs, or walking on the level; the texture and compositions of walking 

surfaces; the speed of movement; and the body temperature of the wearer. Under relatively easy 

walking conditions, the increase in heart rate while carrying an extra 60 pounds (27 kilograms) of weight 

is a heart rate increase of 10 percent of the maximum. 

How Respirators Affect Respiration [Johnson et al. 2001a] 

Air-purifying respirators (APRs), except filtering facepiece respirators (FFRs), have inspiratory resistances 

dominated by filter resistances, with a typical value of 3.5 centimeters (cm) of water-seconds per liter (L) 

(or 50 millimeters H2O at 85 L/min flow rate) [Johnson et al. 1999b]. Exhalation resistances of the 

exhalation valves may be somewhat less than 1.5 cm H2O-sec/L [Caretti et al. 2001]. Powered airpurifying respirators (PAPRs) may have much lower inhalation resistance, but the same exhalation 

resistance [Johnson et al. 2005a]. Self-contained breathing apparatus (SCBAs) may have zero or negative 

equivalent resistance, but very high pressures to exhale against. Although exhaling against high 

pressures is uncomfortable at rest (when respiration usually includes passive exhalation), high exhalation 

pressures can be tolerated better during exercise (when the respiratory muscles for exhalation contract 

actively). Previous work seems to indicate that inspiratory and expiratory resistance effects are 

equivalent [Caretti et al. 2007], although testing using very high expiratory resistance resulted in severely 

degraded performance [Johnson et al. 1997d]. 

The effects of APR inspiratory resistance on performance are felt most at very intense exercise (80-85 

percent maximum oxygen consumption) [Johnson et al. 1992a, 1999a, 2000b]. Performance time 

decreases linearly with increased inspiratory resistance at this exercise intensity. A resistance level of 3.5 

cm H2O- sec/L is expected to result in a 30 percent performance decrement [Johnson et al. 1999b]. 

Because of this, one might expect performance with PAPRs to be better than with APRs, but this has yet 

to be definitively shown, and the extra weight of the blower and tubing may counteract at least some of 

the advantage of lower resistance [Johnson et al. 1999a]. 

Extreme environmental conditions may drastically shorten PAPR battery capacity. If the battery fails to 

provide sufficient current to power the blower motor, the filtration capacity of the device would still be 

present. However, it would become an unpowered APR with significant inspiratory resistance and dead 

volume and carbon dioxide accumulation (especially if there is no check valve located between the 

blower and the wearer). Breathing under this circumstance may become more of a burden, but the 

respirator must still be worn to provide respiratory protection. Wearers must be trained to leave the 

contaminated area immediately if this occurs. 

Extra inspiratory resistance promotes hypoventilation of the wearer (lower volumes of air breathed and 

smaller amounts of oxygen used). This can result in an earlier transition from aerobic (using oxygen) to 

anaerobic (no oxygen needed) respiration, and faster progress toward the maximum tolerance for 

exercise (maximum oxygen debt) [Johnson et al. 1999a]. Consequently, higher resistance filters can be 

expected to need smaller filtering capacity because of the reduced air breathed through them. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 113 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Facepiece dead volume accumulates exhaled carbon dioxide in the voids between the respirator and the 

face and returns it to the respiratory system during the next inspiration. This carbon dioxide then acts as 

a respiratory stimulant. Because carbon dioxide is a psychoactive gas, dead volume may also produce 

discomfort and a performance decrement at low-intensity work [Billings 1973]. A typical value for APR 

respirator dead volume is 350 milliliters. Such a dead volume is expected to reduce performance time by 

19 percent at 80 to 85 percent of maximum oxygen uptake [Johnson et al. 2000a]. Dead volume may be 

reduced by choosing a PAPR over an APR. 

Intense exercise uses more air than does moderate exercise [Mackey et al. 2005], and because very 

intense exercise metabolism has a higher anaerobic component than does moderate exercise, the air 

that is used is not consumed as efficiently as it is at lower intensity [Johnson et al. 2005d]. This can 

severely limit the time spent immersed in the emergency environment. Some SCBAs recycle spent air, 

but there is still some air blown off through exhalation valves (no closed-circuit SCBAs have been 

approved for CBRN use as of this writing). The net result of spent air expulsion is that tank air depletes 

much more rapidly at high work rates than at moderate work rates. 

Heat and Cold and CBRN Equipment [Johnson 2007; Johnson et al. 2001a] 

Use of respirators in non-temperate conditions can lead to special problems [Johnson et al. 1992b]. Cold 

conditions can cause fogging of full facepiece respirators, which leads to severe dissatisfaction with 

respirator use [Johnson et al. 1994, 1997b]. Nose cups inside the facepiece are designed to eliminate 

fogging, but are not always effective. Fog-proof lenses are available on some models. Fog-proofing 

solutions that can be applied to the face shield are also available. Cold can also cause valve sticking and 

stiffen the rubber facepiece material to the point that it prevents a good facial seal. Cold rubber has a 

higher thermal conductivity than does still air, so in still, cold air the face may be cooled by the 

respirator. In a cold wind, however, the facepiece may add a small amount of insulation to the face. 

Use of respirators in hot conditions leads to several difficulties: 

1. Discomfort has been related to facial temperatures inside the facepiece. Facial skin temperatures are 

more important for comfort than skin temperatures in other parts of the body. PAPR blowers send 

filtered air over the face that evaporates sweat and cools the face [Johnson et al. 1999a, 2005a]. SCBA 

air expands and cools when released from the cylinder; this cool air can help alleviate facial 

discomfort. Some SCBAs have coolant packs used to further cool supplied air before it reaches the 

facepiece. APRs, however, have been found to be uncomfortable in the heat because they do not 

supply cool air. 

2. At moderate work rates (50 to 70 percent of maximum oxygen uptake, or maximum exercise 

capacity), respirators impede the loss of heat from the face and can result in hyperthermia occurring 

sooner. This is not usually a problem except when the rest of the body is sealed in protective clothing. 

With no easy means to lose heat, the body can overheat, especially in hot and active conditions. 

3. Sweat produced inside the facepiece can accumulate and cause discomfort, interfere with breathing, 

and cause exhalation valve sticking [Johnson et al. 1997c]. Accumulated sweat can cause a respirator 

facepiece to slip on the face and promote leakage. 

Heat can also affect the ability to recognize dangers, make coordinated movements, and perform 

manual tasks. As deep body temperature increases, dexterity, cognition, and motor skills degrade 

significantly, as shown in Figure 7-2 [Johnson et al. 1992b]. One of the most dangerous effects of 

overheating is disorientation, and not being able to recognize the direction to safety in the event of 

extreme danger. This inability to recognize safe passage has contributed to past deaths [MSHA 2002]. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 114 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Figure 7-2. Effect of Body Temperature on Dexterity, Cognition, and Motor Skills 

Humidity in the air has a profound effect on the ability of the body to lose heat when there is exposed 

skin or the respiratory system breathes ambient air directly. When humidity tends toward saturation 

(100 percent relative humidity), there is less ability to evaporate moisture into the air. Sweating heat loss 

and respiratory moisture loss are inversely related to the amount of moisture in the air. 

When fully encapsulated in CBRN protective gear, however, the likelihood that there will be areas of 

exposed skin is small. In that case, the effect of ambient relative humidity on heat loss is little to none. 

APR and PAPR filters remove at least some of the humidity from the air that is inhaled by the wearer. 

High humidity conditions may promote respirator lens fogging. 

Intense Activity with CBRN Equipment 

First responders can never be sure what conditions await them when called to an emergency. In at least 

some of these incidents, there will be a need for urgency and extraordinary measures. High exertion 

would be appropriate until the situation can be controlled. Under these extreme haste conditions, 

several problems may occur: protective equipment may be put on incorrectly, exertion may reach levels 

that cannot be sustained, body overheating may occur, and respirators may slip on the sweaty face. Each 

of these can have severe consequences, but these occurrences are less likely with ongoing training and 

drills. 

The responder should be careful with his or her equipment, because it stands between the wearer and 

either loss of life or a remaining life of disability. Some respirator leakage is expected to occur, especially 

as sweat builds up on the face and the respirator does not follow sudden head movements exactly. 

Some leakage can take place through the exhalation valve, especially when it becomes wet from sweat. 

Both SCBAs and PAPRs are positive pressure devices, but this does not mean they cannot leak at local 

spots around the peripheral face seal. Respirator leakages have been measured in the workplace, but 

they have not been found to significantly affect the overall protection given [Janssen and McCullough 

2010]. This issue may become a little more critical in situations where the contaminant is more 

dangerous than those in industrial environments. Of particular interest is the leakage from the face seal 

of oxygen-enriched gases in SCBAs into combustible atmospheres. Although SCBA gases are kept to an 

oxygen concentration that does not promote fire, the emergency responder should be aware of the 

possibility that a dangerous condition could suddenly arise. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 115 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Communications with Respirators [Johnson et al. 2001a] 

Full facepiece respirators interfere with visual cues during speaking and listening. It thus becomes more 

difficult not only to recognize what is said, but also who is saying it. Distance and intelligibility are 

interrelated: longer distances between communicating individuals result in less intelligibility. Speakers 

and listeners should talk in sentences where the message can be conveyed by context as well as by word 

recognition. Sentence context allows speakers and listeners to be separated by 10 times the distance 

compared to communicating by single words [Coyne et al. 1998]. Simple words and phrases are unable 

to be understood 27 percent of the time at distances as close as two feet. 

When telephones or radios are used for long-distance communication, expect a 10 percent error rate in 

recognition of words and a 50 percent increase in the time required to recognize the words [Johnson et 

al. 2000c,d, 2001b]. Because standard telephone and radio equipment dimensions are not entirely 

compatible with respirator facepieces, protocols should be established to let the user know when to 

move the earpiece from the ear and to move the mouthpiece in front of the speech diaphragm. Training 

in the use of these protocols is essential. 

Special communication equipment is available from some manufacturers and some respirators have 

speech diaphragms or are made of materials that enhance speech transmission. 

If responders are close enough to see each other, a lot of communication can take place with hand 

signals. There are some generally accepted hand signals that denote easily understood, simple messages 

(examples of these are thumbs up for agreement, a finger across the throat for danger, an upright palm 

to indicate “stop,” and pointing to indicate direction). These will be harder to see in a smoky 

environment and with gloves on, so there is a distance penalty even with hand signals. 

One of the most difficult impediments to clear communication is accented speech. If speech cannot be 

clearly understood without a respirator, it will be nearly impossible with a respirator. Hand signals may 

serve to overcome speech understanding, but different cultures may also have different interpretations 

of hand signals. 

Vision and Respirators [Johnson et al 2001a] 

Sharp vision is important for some of the tasks required during an emergency. There is a natural 

tunneling of vision that occurs during intense exertion: attention is focused on objects straight ahead. 

Consequently, degradation of vision due to respirator use during high exertion has little effect on the 

ability to complete the required task [Johnson et al. 1997a]. Under normal conditions, this might be 

advantageous to task performance. In a situation where dangers can come flying in from all directions, 

there may be difficulty recognizing peripheral threats. 

Vision is extremely important for performing low-physical intensity tasks, such as computer work, 

console monitoring, and reading [Dooly et al. 1994; Johnson et al. 1993, 1994, 1997b, 1998]. There are 

many aspects of vision, including visual acuity, peripheral vision, and color detection, and some or all of 

these may be needed. Respirators should be selected to accommodate requirements for peripheral 

vision, acuity, and color recognition. 

Responders requiring corrective lenses while wearing respirators must not wear spectacles with temple 

bars or straps that come between the sealing surface of the respirator and the face. Instead, special 

corrective lens mounting kits may be used with full facepiece respirators. These may not be entirely 

satisfactory for some wearers. Those who can wear contact lenses can usually do so while wearing a 

respirator mask. As long as the insides of respirators are kept clean, dust particles will not be present to 

cause difficulties with contact lenses. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 116 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Dust, mist, smoke, condensation, or water flowing down over the facepiece lenses can degrade visual 

acuity during an emergency. Under such conditions, task performance can be expected to be seriously 

degraded, as shown in Figure 7-3 [Johnson et al. 1994]. Extra training under these conditions might be 

warranted. Disorientation in a low-visibility environment is common, and may make it difficult to know 

how to move or which is the safest direction to go. Although visual acuity has little to no effect on 

performance of intense physical activity, wearing a full facepiece respirator while walking, running, or 

driving can erode visual acuity somewhat, probably due to the pull of the facepiece on the face [Johnson 

et al. 1997a]. Recognition of objects or signs while wearing a respirator and walking or driving cannot be 

expected to happen as quickly as without a respirator. 

Figure 7-3. Performance for several tasks as visual acuity varies while wearing 

respirators. The Snellen eye chart denotes better vision for higher line numbers. Control 

panel recognition and performance ability is particularly sensitive to visual acuity. 

Other Equipment and CBRN Gear [Johnson et al. 2001a] 

Respirators can interfere with responder activities because of their bulk or weight. Use of respirators in 

tight places is difficult and can temporarily disrupt facial seals when bumping against other objects. 

Respirators may interfere with sighting equipment or with other measuring devices. Contrarily, the 

impact resistance of the lenses of many full facepiece respirators can be a positive attribute in situations 

where objects or debris may hit the face. 

CBRN protective clothing is also bulky and heavy, and can impede responder progress. Small spaces must 

be larger for a protected responder to fit through. Gloves make fine hand or finger movements nearly 

impossible. 

Anxieties [Johnson et al. 2001a] 

Anxious individuals should not be asked to wear respirators. Studies have shown that anxiety level is a 

very reliable indicator of difficulty encountered while wearing a respirator [Morgan and Ravan 1985]. 

Extremely anxious individuals do not perform for as long or at the same work rate as low-anxiety 

wearers [Johnson et al. 1995a]. A supervisor, therefore, should probably avoid these problems by 

allowing their anxious employees to perform jobs that do not require respirators to be worn. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 117 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Personal Procedures [Johnson et al. 2001a] 

The facial area inside a respirator is usually not accessible from the outside unless the face seal is broken. 

Thus, eating, drinking, scratching one’s face, blowing one’s nose, or rubbing an eye are not possible while 

wearing full facepiece respirators. One exception to this is certain respirators that have a drinking tube 

incorporated into their designs. 

As long as periodic breaks are allowed, respirators should not add to the fatigue that accompanies longterm work [Johnson et al. 1997b]. Food or drink can be ingested during those breaks, and energy levels 

maintained. While it is unlikely that responders would be needed to work for hours at a time without 

breaks, if such were the case, then blood glucose could fall to dangerously low levels (hypoglycemia), and 

work could not continue efficiently. 

The inaccessibility of the face may generate considerable tension in the mind of the wearer, especially if 

the reason to access the face is due to some particularly sensitive need. Dust or dryness in the eyes of 

contact lens wearers, runny noses, or unbearable pressure to parts of the face can be particularly 

distressing [Johnson and Cummings 1975]. If the situation does not allow the wearer to leave the 

hazardous environment to take care of the problem, then considerable anxiety may develop. 

Another personal issue that generates much controversy is the presence of facial hair (e.g., beards or 

goatees) on a person who must wear a respirator. Every respirator use regulation or standard prohibits use 

of tight-fitting respirators with facial hair that comes between the sealing surface of the facepiece and the 

face, or that interferes with valve function. Many experimental studies with negative-pressure respirators 

(including air-purifying and atmosphere-supplying respirators) show the protection provided by the 

respirator is reduced when facial hair is lying between the sealing surface of the respirator facepiece and 

the wearer’s skin. Some studies have found that when pressure inside the facepiece was positive, there 

was no degradation of the protection provided. However, not all positive-pressure respirators can actually 

maintain positive pressure inside the facepiece during the entire breathing cycle and at all work rates. For 

this reason, use of tight-fitting, positive-pressure respirators by people with facial hair is unacceptable. The 

protection provided by respirators with hoods and helmet is not affected by facial hair. 

Control and Training Issues [LaTourrette et al. 2003] 

The special nature of total protection required by CBRN emergencies adds additional burdens on the 

responders and on those who are managing the effort. Wearing the full CBRN protective gear ensemble 

makes activities much more burdensome than if the gear was not worn. Training in the fully protected 

mode can familiarize the responder with this burden so that it does not come as a surprise during an actual 

emergency [Johnson et al. 2005b; Rebar et al. 2004]. Similarly, line supervisors and emergency managers 

must take special care to protect those who are placing themselves at risk. Additional manpower is 

required to ensure that each individual is not overwhelmed by the challenges present. Every effort must 

be made to remain in contact with each responder under the supervisor’s responsibility. 

According to the RAND report in the aftermath of the World Trade Center attacks, communications 

among firefighters and to and from control centers was one of the biggest issues requiring improvement 

[LaTourrette et al. 2003]. As mentioned before, communications while wearing respirators are difficult at 

best, and, unless first responder training includes communications training, this issue could repeat in the 

next general emergency. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 118 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

The uncontrolled nature of extreme emergencies and terrorist actions makes precise planning and 

training very difficult. CBRN equipment is only one element to be taken into account. Maintaining some 

semblance of order and situational control can be challenging. Understanding the limitations imposed by 

normal physiological adjustments to exercise, as modified by CBRN equipment use, can help planning 

and training programs. 

Physical stress in the World Trade Center conflagration accounted for one-quarter of the firefighter 

injuries and one-half of their immediate deaths [Park 2001]. At this point, there are no good solutions to 

this problem. CBRN equipment is heavy and hot, and not likely to become less so any time soon. The 

immediate problem is protection. The equipment provides that. Training and responder tactics must be 

used as much as possible to overcome the limitations imposed by the equipment. It cannot be expected 

that first responders operate as if they were not wearing the equipment. Without the equipment, they 

could lose their lives; with the equipment, they must act carefully. 

Physiological Reponses to Work Activity 

Before a brief discussion of ergonomics and work physiology, there are two things to keep in mind about 

heavy exertion while wearing respirators and protective clothing: 

1. Work cannot usually be performed as long or as hard while wearing a respirator compared to when 

respirators are not worn. Wearing protective clothing plus respirators makes this situation even 

worse. Either more time must be allowed for a particular task or more responders must be assigned 

to the same task. 

2. There is a great deal of wearer variability. Some wearers can tolerate respirator high inspiratory or 

expiratory resistance or pressure levels, while others cannot. Some wearers are much more anxious 

about wearing respirators than others. Some wearers can tolerate hot, humid conditions inside 

protective clothing, whereas others cannot. Even with the stringent selection process for many 

emergency personnel, this variability persists. Additionally, emergencies sometimes require people to 

respond who have not been through the selection process. Because of this variability, each responder 

must be treated as an individual. 

Work/Performance Time Tradeoff

Very hard work cannot be performed for as long a time as work of lesser intensity [Johnson 1976, 2007; 

Johnson and Dooly 2006]. This is true even when unencumbered by CBRN equipment. Figure 7-4 shows 

that for different activity levels, there are corresponding physiological limitations consisting of a 

cardiovascular limitation for very intense work, respiratory limitation for intense work, thermal limitation 

for moderate work, and what is generally called irritation limits for low-level activity. Protective masks 

and clothing generally shorten the time that a particular activity level can be sustained. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 119 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Figure 7-4. Schematic Representation of Performance Time While Exercising 

and Wearing a Protective Mask [Johnson and Cummings 1975] 

Physiological Adjustments 

The human body is attuned to performing physical labor [Hurley and Johnson 2006]. What follows the start 

of muscular activity is a coordinated series of adjustments involving all parts of the body, including the 

heart, blood vessels, lungs, digestive system, nervous system, and kidneys. The ones with the most direct 

bearing on exercise adjustments are described below. 

Metabolism [Johnson 2007] 

Muscular movement requires energy. This energy comes from an energy storage molecule called adenosine 

triphosphate (ATP). When the supply of ATP is exhausted, muscle activity ceases. It is important, therefore, 

to replenish the ATP supply as quickly as possible in order to maintain muscular work. There is also another 

energy-rich compound in the muscles called creatine phosphate that can act to replenish the ATP supply 

extremely quickly. When the muscle starts working, there is enough ATP in the muscles to sustain the work 

for 0.5 seconds. There is enough creatine phosphate present to keep the muscle working for up to two 

minutes. After that, other energy-forming mechanisms are necessary to replenish the ATP supply. 

This other energy comes from stores of glucose in the blood, glycogen (an animal form of starch) in the 

muscles and liver, fats in the form of triglycerides in fat tissue, and body proteins. In order to extract the 

energy from these compounds, they must be respired. There are two kinds of cellular metabolism 

(sometimes called cellular respiration): anaerobic and aerobic. The difference between the two is that 

aerobic metabolism requires oxygen and anaerobic metabolism does not. Oxygen delivery to the 

muscles begins in the lungs, continues in the blood, and is finally delivered to the muscles, as shown in 

Figure 7-5. If enough oxygen can be delivered to the tissues, then aerobic metabolism can keep up with 

the energy demands of the muscles. However, there are limits to the rate that oxygen can be supplied, 

called the maximum oxygen uptake. Once the maximum oxygen uptake is reached, additional muscular 

energy must come from anaerobic metabolism. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 120 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Figure 7-5. Oxygen delivery to the muscles is a multistep process, beginning with gas 

exchange in the lungs, being transported in the blood, and finally being used in the 

muscles. 

Very heavy exertion requires at least some anaerobic metabolism because oxygen demand exceeds the 

maximum oxygen uptake. This is called the anaerobic threshold. Anaerobic metabolism yields 18 times 

fewer ATP molecules than aerobic respiration, and so is not nearly as efficient. However, it does allow 

movement to continue, at least for a while. 

One of the end products of aerobic metabolism is carbon dioxide, which can be removed during 

exhalation. Carbon dioxide levels in the exhaled breath rarely reach more than four or five percent, even 

at the extreme. However, if it were to climb much higher, carbon dioxide could cause disorientation, 

confusion, and even death. 

The main end product of anaerobic metabolism is lactic acid that is released from the muscles into the 

blood. There are buffering mechanisms in the body that tolerate lactic acid additions, but these 

mechanisms have limited capacity. Once this capacity is reached, there is no other source of energy for 

the muscles and all muscular activity must cease. This capacity to tolerate lactate is called the maximum 

oxygen debt because all the lactic acid must be reformulated into glucose at the end of exercise, and this 

requires oxygen. 

Buffering the blood against lactic acid formation during anaerobic metabolism produces extra carbon 

dioxide that can be exhaled. This extra carbon dioxide acts as a respiratory stimulant that leads to 

hyperventilation, or harder and deeper breathing. 

All these processes proceed each time a person moves actively [Dooly et al. 1996; Johnson et al. 1995b]. 

They are much more efficient for younger people than for older people. Maximum oxygen uptake for 20-

year-olds is about 2.5 liters per minute, but declines nearly linearly to about 1.7 liters per minute at age 

65. Well-trained individuals can have maximum oxygen uptakes up to twice these values. In addition, the 

maximum oxygen debt that can be incurred by an individual declines with age and is also affected by 

training. 

Metabolic responses during exercise, and especially during emergencies, are modified by the release of 

the adrenal hormones adrenalin (epinephrine) and cortisol. These hormones increase metabolic rate, 

increase the rate and force of heart contractions, enhance the availability of blood glucose, reroute 

blood from the gut to the muscles, and mobilize the nervous system. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 121 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

The combined actions of these hormones can affect physical, emotional, and cognitive functions. 

Muscular strength declines with age, making task performance less efficient when more muscles must be 

recruited to perform a task [Hurley and Johnson 2006]. Muscular power can be restored relatively 

rapidly with strength training. 

Drugs and medicines can also affect body metabolism, as can illness. Products of cigarette smoking and 

caffeine also affect metabolic rate [Scott et al. 2002]. 

Cardiovascular Adjustments [Johnson 2007] 

The heart adjusts to the physical demands of exertion by increasing its cardiac output, or the volume 

rate of blood flow through the arteries, capillaries, and veins. This increases the rate of glucose and 

oxygen supplied to the muscles, and the rate of removal of lactate and carbon dioxide from the muscles. 

The heart rate increases nearly linearly with work rate, beginning to increase nearly as soon as work rate 

increases. This is due to kinesthetic neural sensors in the muscles and joints that signal the fact that 

increased oxygen demand is on its way, despite the fact that there is as yet no reduction in blood oxygen 

concentration or rise in carbon dioxide concentration. Once the concentrations of these gases change, 

then control of heart response is determined by chemical sensors in the aorta, in the carotid arteries in 

the neck, and in the brain. 

The stroke volume of the heart or the volume of blood pumped for each heartbeat, increases initially at 

the start of exercise, but soon reaches its maximum level. Thereafter, increases in cardiac output are 

determined only by heart rate. Cardiac output at rest is about five or six liters per minute, but can rise to 

25 liters per minute during strenuous activity. Blood volume in a somewhat smallish 150-pound (70 kg) 

person is about 5.6 liters. Hence, it takes about one minute at rest and 12 seconds during exercise for 

blood to make the loop of the whole circulatory system. 

Larger people generally have larger hearts and larger stroke volumes. Well-trained individuals have 

lower resting heart rates and higher resting stroke volumes. Older individuals can have somewhat lower 

cardiac efficiencies than younger individuals. 

If body temperature rises due to overheating, then there is a secondary rise in heart rate, which puts 

additional stress on the heart. The water from sweat is derived from the blood plasma, causing the 

blood to thicken somewhat during prolonged exercise. This also increases stress on the heart, but is 

alleviated by drinking sufficient amounts of liquid, some of which can be drunk before the responder 

answers the emergency. 

Cardiovascular adjustments also include shunting the blood from maintenance activities, such as 

digestion and kidney function, to working muscles where it is needed. Much of the blood in the 

circulatory system at rest is located in the leg veins; during exercise, most of the blood is shifted to the 

arteries. These changes occur very quickly after activity begins. Release of the hormones epinephrine and 

cortisol in an emergency speeds the heart and constricts some blood vessels to shunt blood to the arms 

and legs. 

Oxygen delivery to the working muscles can be limited by the maximum cardiac output, given as the 

maximum heart rate times the maximum stroke volume. Once this maximum has been reached, 

metabolism continues anaerobically. Depending on the muscles being used and the vascular 

structure serving those muscles, there may be local regions of anaerobic metabolism occurring while the 

muscles as a whole are still aerobic. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 122 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Respiration [Johnson 2007] 

Respiration also increases as exercise progresses, but respiratory responses lag behind activity level 

changes by about 45 seconds. There are many respiratory responses that occur: the respiration rate 

increases [Christie1953], the tidal volume (or the amount of air breathed during each breath) increases 

up to a maximum amount [Brokaw et al. 2011; Coyne et al. 2006; Johnson 2006; Johnson et al. 2005c] 

the respiratory waveform changes, there are adjustments to the airways, and lung volumes change 

[Johnson 1995]. Many of these changes appear to be stimulated by carbon dioxide concentration of the 

blood, but initial respiratory adjustments occur too quickly for that to be the only determinant; 

kinesthetic sensors may also be important for initial respiratory adjustments [Saunders et al. 1980]. 

Respiration is a multistep process, whereby air is breathed in, travels through the airways, reaches the 

alveoli (the sacs at the end of the lung where gas exchange takes place), diffuses across the alveolar 

membrane, dissolves in the blood, and is absorbed by the hemoglobin in the red blood cells. Carbon 

dioxide diffuses rapidly into the blood, so the concentration of carbon dioxide in the alveoli and the 

blood equilibrate rapidly, even during the most intense activity level. Oxygen, on the other hand diffuses 

more slowly than carbon dioxide, so its concentration in the blood is lower than in alveolar air during 

inhalation. Diffusion rates of both gases change somewhat with activity level, with those for men being 

somewhat higher than those for women. 

Inhaled air is oxygen rich and carbon dioxide poor. Exhaled air is oxygen poor and carbon dioxide rich. 

Because airflow in the airways is bidirectional, the first air that reaches the alveoli is the same as the last 

air that was exhaled during the previous exhalation. This is an indication of the dead volume of the lung, 

or that volume that stores carbon dioxide from the previous breath. Dead volume for the average adults 

is about 180 milliliters, but dead volume of respirators can add to the effective dead volume of the 

respiratory system and affect performance. 

Carbon dioxide is a very powerful respiratory stimulant [Billings 1973]. Increasing the concentration of 

inhaled carbon dioxide increases lung ventilation much more than oxygen deficiency. Metabolically 

produced carbon dioxide is even more effective than inhaled carbon dioxide at stimulating respiration. 

This is critical for additions of external dead volume, which transforms exhaled metabolic carbon dioxide 

into carbon dioxide inhaled during the next breath. Once the anaerobic threshold is reached, blood 

buffering makes it appear that metabolic carbon dioxide increases, and respiration is stimulated so much 

that lung ventilation increases dramatically as work rate intensifies. 

Working muscles change their efficiencies over time as they heat and tire. Additional oxygen demands of 

muscles that have been worked for several minutes increase the need for the respiratory system to 

respond. This leads to a secondary rise in lung ventilation that continues well into the exercise duration. 

Moving the chest wall, lung tissue, and air in the airways requires energy. This energy is equivalent to about 

one to two percent of the total body oxygen consumption at rest, but increases during intense activity to 

eight to ten percent. For people with obstructive pulmonary disease, the percentage at rest can be 18-20 

percent. These people cannot perform strenuous exercise. Adding external resistance or dead volume 

from a respirator (APR) or external pressure (SCBA or PAPR) increases the amount of work that must be 

supplied to breathe [Johnson and Masaitis 1976; Johnson and McCuen 1980, 1981]. Oxygen to supply the 

needs of the respiratory system cannot be used to supply the working muscles, so respiratory demands 

can definitely limit the rate of work that can be expected of a responder. 

The work of respiration is supplied by the respiratory muscles. These include the diaphragm, the 

intercostals, and the abdominals. Inhalation is caused mainly due to the straightening of the diaphragm 

in the chest. Exhalation at rest is passive; that is, the force to propel the air to leave the lung comes from 

the elasticity of the stretched lung. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 123 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Exhalation during exercise needs to happen a lot faster than during rest, so it becomes active when the 

abdominal muscles push air out of the lung [Johnson and Berlin 1974; Johnson and Curtis 1978]. Due to 

this difference, it is much easier and comfortable to breathe against PAPR or SCBA positive pressure 

during exertion than during rest. 

The airways are reactive, and change during exercise. They can constrict somewhat to reduce dead 

volume, and thus lower wasted breathing effort, but as they constrict, they resist airflow and increase 

the work of breathing, so there is a dynamic level of airway tone achieved [Johnson et al. 2012b]. These 

same airways may constrict to protect against respiratory irritants reaching the lung and cause the same 

symptoms as a severe asthma attack. 

Thermal Responses [Johnson 2007] 

The large skeletal muscles are only about 20 percent efficient. Of the energy supplied to the muscles, 

approximately 80 percent ends up as heat [Johnson and Berlin 1973; Johnson et al. 2012a; Scott et al. 

2008]. Thus, heat loss mechanisms are necessary to maintain thermal equilibrium of the human body. 

These mechanisms include vascular adjustments, sweating, and voluntary responses. Voluntary 

responses include moving to cooler locales, stretching out to lose more heat, drinking cool liquids, or 

removing heavy clothing. These responses will generally be unavailable to emergency responders. 

There is a thermal mass to the body that requires some time for heat to build up and cause dangerous 

body temperatures. There is a normal six to ten minutes of activity that can occur before deep body 

temperature significantly rises. Skin temperature probably increases during this time. If sufficient heat 

cannot be lost to the environment, then body temperature will continue to rise until it reaches 

dangerous levels. Heat exhaustion can set in when core body temperatures rises above 100.4°F (38°C), is 

characterized by the abnormal performance of at least one organ system, and may signal impending 

heat stroke. A core body temperature of 104°F (40°C) is expected to result in a 50 percent casualty rate 

[Goldman 1975]. This condition is characterized by disorientation, convulsions, loss of body temperature 

control, and death. At body temperatures lower than this, performance efficiency still suffers (refer to 

Figure 7-2). 

Heat can be lost from the body by convection (usually air movement), radiation (as to a cold clear sky), 

or evaporation. Convection and radiation heat loss depend on the difference in temperature between 

the surface losing heat and the surrounding fluid (usually air, but in a pool, for example, water). Thus, 

one adjustment the body makes during thermal stress is to warm the skin surface. It does this by 

shunting blood from deep veins into surface veins. This is why veins on the surface of the hands seem to 

stand out more in hot weather than in the cold. There is also a small, but significant, amount of 

convective heat loss from the respiratory system as air is breathed. 

Evaporating water absorbs a large amount of heat, making sweating effective as a heat loss mechanism. 

Sweating heat loss on the surface of the skin is nearly 100 percent effective for losing heat. Sweating 

through clothing cools the clothing surface where the evaporation actually takes place, and only partially 

cools the skin. Sweat that drops from the skin is completely ineffective for heat removal. The amount of 

sweating depends on the cooling necessary, and different parts of the skin are recruited at different 

times to produce sweat. When fully recruited, the maximum cooling that can be obtained from sweating 

is equivalent to nearly 12 times the body heat production at rest (or 11.4 mets). 

Women have higher percent body fat than men. They use this body fat as insulation between their body 

cores and the outside environment. To lose heat, therefore, women depend more on vascular 

adjustments than men. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 124 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Men sweat more than women and lose a larger fraction of their heat that way. Acclimation to hot 

environments can improve sweating efficiency by increasing both the rate of response and amount of 

sweat produced. 

Some responders may not need to wear protective clothing with their respirators. However, covering the 

entire body, and moving into a hot, burning environment eliminates nearly all possibility of heat loss 

natural to the human body. Other means must be provided, such as supply of cool air from an SCBA, or 

body temperatures must be closely monitored. An alternative is to limit heat exposure time and to 

provide adequate rest cycles. 

Some emergencies may require response in very cold temperatures. At the beginning, cold temperatures 

may limit movement and dexterity. However, heat produced during activity and the extra insulation 

afforded by protective clothing and respirators soon overcome cold temperature effects on the body. 

Surface blood vessels in the head do not constrict in the cold, as do similar blood vessels in other parts of 

the body. Hence, nearly half of the body’s heat loss in the cold can come from the head. Covering the 

head and face with protective equipment helps to insulate against this large amount of heat loss. 

Work/Rest Cycles [Johnson 2007] 

As shown in Figure 7-4, more intense work cannot be sustained as long as less intense work. If 

responders are expected to work very hard for a while, they must also be in a position to rest or at least 

slow down for some time. This can be a problem in dire emergencies, because anaerobic work continued 

for too long can result in the maximum oxygen debt being reached. Then the responder would not be 

able to work anymore until he or she recovers sufficiently. Lives could be lost if it reaches this point. 

The amount of time that a person can be expected to work is related to the fraction of the maximum 

oxygen uptake represented by the task being performed. Thus, performance time involves the size of the 

individual as well as age, sex, and physical conditioning. In general, men have higher maximum oxygen 

uptakes than women, but they have larger bodies that use more oxygen to move around. Older people 

have lower maximum oxygen uptakes than younger people. Responders in better physical condition 

have higher maximum oxygen uptakes and are able to perform tasks with lower oxygen use than less 

physically able responders. This emphasizes the need for constant physical conditioning of those who are 

on call to deal with emergencies. Remember, however, that emergencies such as acts of terrorism are 

likely to occur almost anywhere and at any time. People who are not physically conditioned or trained to 

respond properly may be pressed into service. Thus, it is up to the supervisor to be aware of their 

limitations; emergency management personnel should include this contingency in their planning process. 

Work performance times can range from forever at rest, to four hours walking at three miles per hour, to 

23 minutes for cross-country running, to 10 minutes climbing stairs. These are typical times for an 

unencumbered 40-year-old man. The addition of CBRN equipment can reduce these times to one-half or 

less of the values given, depending on the types of equipment worn. 

Rest times are also dependent on the intensity of the task and the maximum oxygen uptake of the 

individual. In general, the more intense the work, the longer will be the recovery time, but the 

relationship is nonlinear. A task that can be performed for an hour requires at least a 10-minute rest 

period. More intense tasks (with shorter performance times) require longer rest times. One should be 

sure that rest can take place in a safe location, where PPE is not required and cool liquids are available 

to drink. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 125 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Higher work rates are usually associated with higher lung ventilation (breathing harder). Harder 

breathing consumes air from the SCBA tank faster and can reduce protective capacity, or service time, of 

PAPR and APR filters (although this would only be important in very extreme cases). These effects could 

be the most important determination of task performances times. 

One mistake that can be made is to cool an overheated responder by stripping protective clothing and 

venting remaining clothing with cool or cold air. Sweat accumulated on the skin evaporates, overcooling 

the skin. This elicits a reflex that shunts blood from the skin to interior blood vessels in an effort to 

conserve heat. The result is that deep body temperature not only does not cool very fast, but also can 

actually increase by another degree as metabolism continues at a high level for some time after physical 

work ceases. To cool the overheated responder faster after intense work, open protective clothing only 

moderately to allow some of the accumulated sweat to evaporate slowly. Of course, venting protective 

clothing, removing gloves, and taking respirators off should only happen in a safe location. 

Prolonged Activity [Johnson 2007] 

Some responders will be assigned support tasks that are not very intense physically. These people will 

have no trouble with maximum oxygen debt, maximum oxygen uptake, or (most likely, unless the 

ambient temperature is extremely warm) excessive body temperature. Different challenges confront 

these responders. First, discomfort is felt more strongly when attention is not directed elsewhere. There 

can be a considerable amount of discomfort associated with wearing respirators, gloves, boots, and 

protective suits. These wearers will have to realize that these pieces of equipment are worn to protect 

them from contaminants that can shorten or reduce the quality of their lives. 

Those individuals prone to anxious feelings may have their anxieties made worse during periods of 

inactivity. Anxieties are the most important threat to protective equipment wear, and extremely anxious 

people should not be asked to wear CBRN equipment if possible [Johnson et al. 1995a; Koh et al. 2006]. 

For those who can tolerate the discomfort and claustrophobic feelings when wearing CBRN equipment, 

there will nonetheless be physical effects of prolonged wear. Many respirators require a tight face seal for 

adequate protection. The site of the face seal may produce rashes and edema in surrounding skin areas. 

These will disappear with time once the equipment is removed. Vision can be important at low work rates. 

There may be tasks that require a broad visual field or fine discrimination among various lights, switches, 

or objects. Respirators interfere with vision in various ways, but visual acuity at low work rates can be 

compromised by lens fogging, dust or films on the lenses, or wearing of improper corrective lenses 

[Johnson et al. 1997a]. Sweating while wearing respirators in cold drafts can easily incur moisture 

condensation inside the facepiece. Dusts and precipitates that are of no respiratory consequence to the 

wearer can obscure vision if it cannot be wiped from the lenses. 

Physiological Limits 

Respirator masks may look like relatively simple devices. However, they are complex pieces of 

equipment. They can interfere with vision, speaking and hearing, respiration, heat loss, eating and 

drinking, sneezing, scratching one’s face, other equipment, and a feeling of well-being. Interference with 

each of these functions can be the source of impaired performance when working while wearing a 

respirator. Both respirators and other protective clothing can be heavy, adding weight and bulk to make 

movements even harder than they would have been without them. Each protective component insulates 

not only against contaminants, but also against heat loss. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 126 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Cardiovascular [Johnson 2007] 

There is a maximum heart rate that can be achieved by an individual. This is age dependent, generally 

predicted as 220-(age of the individual). Younger people therefore have higher maximum heart rates. 

Once this maximum heart rate is reached, cardiac output no longer increases, and oxygen delivery to the 

muscles becomes static. Anaerobic metabolism is incurred, terminating when the maximum oxygen debt 

in reached. Cardiovascular-limited exercise normally terminates in two to four minutes. 

Respiratory [Johnson 2007] 

The most important function of the respiratory system is the removal of carbon dioxide from the body. 

Adjustments during exercise increase depth and rate of breathing in order to expel this gaseous end 

product of aerobic metabolism. Exercise exhalation becomes actively supported by the abdominal 

muscles, spewing carbon dioxide at faster rates as exercise intensifies. At some point, the rate at which 

air can be exhaled becomes limited by the distensible airways in the respiratory system. Any further 

increase in abdominal pressure cannot increase expiratory flow rate [Lausted et al. 2006]. Thus, for 

normal individuals, there is a limitation when exhalation time decreases to one-half second or so 

[Johnson and Berlin 1974; Johnson and Curtis 1978]. 

Carbon dioxide cannot be expelled any faster than this minimum exhalation time allows. Respiration 

does not usually limit work performances of healthy individuals, but respiration can limit work time 

when respirators are worn. Respiratory-limited work usually lasts 5-20 minutes. 

For people with respiratory impairments, the maximum pressures that can be generated by the 

respiratory muscles can limit the rates at which they can breathe through external resistances or against 

external pressures. These people are not likely to be found as first responders, but may volunteer from 

onsite spectators. 

Thermal [Johnson 2007] 

The most important work limitation associated with heat is deep body temperature. It must be 

prevented from reaching 40°C. A conservative limit might be 39.2°C (102.5°F). Beyond this, thermal 

discomfort becomes overwhelming and death may ensue. Muscular efficiency is reduced at high 

temperatures and judgment becomes impaired. Thus, the overheated individual cannot be expected to 

recognize his or her own dangerous situation. 

Because of the thermal capacity of the body to store heat, it takes a while before body temperature rises 

to the point where it can become limiting. Heat-limited work usually occurs in the 10-minute to 2-hour 

time range. 

Long-Term Limits [Johnson 2007] 

Physiological limits to long-term exercise deal with limitations on blood glucose levels and muscle 

glycogen stores. Dehydration or electrolyte depletion may occur. These are difficult to quantify for any 

individual, but frequent eating and drinking can deter them from occurring. 

Psychological effects are also important. Feelings of fatigue are common, as are feelings of anxiety and 

discontent. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 127 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Summary 

Physical exertion involves the entire body in a coordinated fashion. Adjustments made during work or 

exercise can be profound, but the limitations of exercise can be modified or overcome by training and 

proper selection of equipment. Familiarity with the physiological adjustments that occur can lead to 

enhanced effectiveness and larger return on investment for both manpower and equipment. As long as 

humans are involved in emergency responses, accommodation must be made for the adjustments that 

characterize their physical abilities. Training is important to improve the wearer’s ability to respond in an 

emergency, but does not eliminate the basic physiological and psychological limits to performance. 

References 

ALA [2012]. Lung disease. Chicago, IL: American Lung Association http://www.lung.org/lung-%20disease. 

accessed 24 March 2012. 

Billings CO [1973]. Atmosphere, in Bioastronautics Data Book, Parker JF, West VR (eds) Washington, DC: NASA, 

Washington, DC, pp 35-63. 

Brokaw E, Johnson AT, McCuen R [2011]. improved prediction of minute volume flow rates, J. Internat. Soc. 

Respir. Prot. 28: 40-47. 

Caretti DM, Coyne K, Johnson A, Scott W, Koh F [2007]. Performance when breathing through different 

respirator inhalation and exhalation resistances during hard work. J. Occupat. Environ. Hyg. 3(4):214-224. 

Caretti DM, Scott WH, Johnson AT, Coyne KM, Koh FC [2001]. Work performance when breathing through 

different respirator exhalation resistances. Am. Indus. Hyg. Assoc. J. 62(4):411-415. 

Christie RV [1953]. Dyspnoea in relation to the visco-elastic properties of the lung, Proc. Roy. Soc. Med. 

46(5):381-386. 

Coyne KM, Caretti DM, Scott WH, Johnson AT, and Koh F [2006]. Inspiratory flow rates during hard work when 

breathing through different respirator inhalation and exhalation resistances, J. Occupat. Environ. Hyg. 3(9):490-

500. 

Coyne KM, Johnson AT, Yeni-Komshiain GH, Dooly CR [1998]. respirator performance ratings for speech 

intelligibility. Am. Indus. Hyg. Assoc. J. 59(4):257-260. 

Dooly CR, Johnson AT, Brown EY [1994]. Performance decrement due to altered vision while wearing a 

respiratory face mask, Mil. Med. 159(5):408-411. 

Dooly CR, Johnson AT, Dotson CO, Vaccaro P, Soong P [1996]. Peak oxygen consumption and lactate threshold 

in full mask versus mouth mask conditions during incremental exercise, Eur. J. Appl. Physiol. 73(3-4):311-316. 

Goldman RF [1975]. Predicting the effects of environment, clothing, and personal equipment on military 

operations, Paper presented to the Eleventh Commonwealth Defense Conference on Operational Clothing and 

Combat Equipment, India. 

Harrison H, Elkabir D [2006]. Products of Combustion. Draft summary information. London, England: Health 

Protection Agency, Centre for Radiation and Environmental Hazards, Chemical Hazards and Poisons Division. 

Hurley BF, Johnson AT [2006]. Factors affecting mechanical work in humans, in biomedical engineering 

fundamentals, Brozino JD (ed) Taylor and Francis, Boca Raton, FL, pp. 66-1 to 66-10. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 128 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Janssen L, McCullough NV [2010]. Half-facepiece air-purifying respirator performance in a lead battery plant. J. 

Occup. Environ. Hyg. 7(1):46-53. 

Johnson AT [1976]. The energetics of mask wear, Am. Indus. Hyg. Assoc. J. 37(8):479-488. 

Johnson AT [1995]. The change in initial lung volume during exercise, IEEE Trans. Biomed. Eng. 42(3):278- 281. 

Johnson AT [1997]. Biological process engineering, an analogical approach to fluid flow, heat transfer, and 

mass transfer applied to biological systems. New York, NY: John Wiley and Sons. 

Johnson AT [2006]. Why peak flow matters, J. Internat. Soc. of Respir. Prot. 23:100-110. 

Johnson AT [2007]. Biomechanics and exercise physiology: quantitative modeling. Boca Raton, FL: Taylor 

and Francis. 

Johnson AT [2011]. Biology for engineers. Boca Raton, FL: Taylor and Francis. 

Johnson AT, Berlin HM [1973]. Interactive effects of heat load and respiratory stress on work performance 

of men wearing cb protective equipment, Edgewood Arsenal Technical Report ED TR 83059 APG, MD 

2l0l0. 

Johnson AT, Berlin HM [1974]. Exhalation time characterizing exhaustion while wearing respiratory 

protective masks, Am. Indus. Hyg. Assoc. J. 35(8):463-467. 

Johnson AT, Cummings EG [1975]. Mask design considerations, Am. Indus. Hyg. Assoc. J. 36(3):220-228. 

Johnson AT, Curtis AV [1978]. Minimum exhalation time with age, sex, and physical condition, Am. Indus. 

Hyg. Assoc. J. 39(10):820-824. 

Johnson AT, Dooly CR [1995a]. Design of respirator masks to incorporate physiological effects: a review. J. 

Internat. Soc. Respir. Prot. 13(2):8-22. 

Johnson AT, Dooly CR [1995b]. Design of respiratory protective masks to improve human performance. In: 

Bronzino JD ed. The Biomedical Engineering Handbook. pp 2321-2334. Boca Raton, FL: CRC Press. 

Johnson AT, Dooley CR [2006]. Exercise Physiology, in biomedical engineering fundamentals, Bronzino JD (ed) 

Taylor and Francis, Boca Raton, FL, pp. 65-1 to 65-9. 

Johnson AT, Masaitis C [1976]. Prediction of inhalation time/exhalation time ratio during exercise, IEEE Trans. 

Biomed. Eng. 23(5):376-380. 

Johnson AT, McCuen RH [1980]. A comparative model study of respiratory period prediction on men exercising 

while wearing masks, IEEE Trans. Biomed. Eng. 27(8):430-439. 

Johnson AT, McCuen RH [1981]. Prediction of respiratory period on men exercising while wearing masks, Am. 

Indus. Hyg. Assoc. J. 42(10):707-710. 

Johnson AT, Benjamin MB, Silverman N [2012a]. Oxygen Consumption, heat production, and muscular 

efficiency during uphill and downhill walking, Appl. Ergon. 33(5):485-491. 

Johnson, AT, Colton CE, Brosseau LM [2001a]. Human factors and Ergonomic Aspects of Respirator Wear, in 

Respiratory Protection: A Manual and Guideline ed., AIHA Press, Fairfax, VA. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 129 
 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Johnson AT, Dooly CR, Blanchard CA, Brown EY [1995a]. Influence of anxiety level on work performance with 

and without a respirator mask, Am. Indus. Hyg. Assoc. J. 56(9):858-865. 

Johnson AT, Dooly CR, Brown EY [1994]. Task performance with visual acuity while wearing a respirator mask. 

Am. Indus. Hyg. Assoc. J. 55(9):818- 822. 

Johnson AT, Dooly CR, Caretti DM, Green M, Scott WH, Coyne KM, Sahota MS, Benjamin B [1997b]. Individual 

work performance during a 10-hour period of respirator wear. Am. Indus. Hyg. Assoc. J. 58(5):345-353. 

Johnson AT, Dooly CR, Coyne KM, Sahota MS, Benjamin MB [1997d]. Work performance when breathing 

through very high exhalation resistance. J. Internat. Soc. Respir. Prot. 15:25-29. 

Johnson AT, Dooly CR, Dotson CO [1995b]. Respirator mask effects on exercise metabolic measures, Am. Indus. 

Hyg. Assoc. J. 56(5):467-473. 

Johnson AT, Dooly CR, Sahota MS, Coyne KM, Benjamin MB [1997a]. Effect of altered vision on constant load 

exercise performance while wearing a respirator, Am. Indus. Hyg. Assoc. J. 58(8):578-586. 

Johnson AT, Dooly CR, Simpson CR [1998]. Generating the snellen chart by computer, Comput. Meth. Prog. 

Biomed. 57(3):161-166. 

Johnson AT, Grove CM, Weiss RA [1992b]. Respirator performance rating tables for nontemperate 

environments. Am. Indus. Hyg. Assoc. J. 53(9):548-555. 

Johnson AT, Grove CM, Weiss RA [1993]. Mask performance rating table for specific military tasks, Mil. Med. 

158(10):665-670. 

Johnson AT, Jones SC, Pan JJ, Vossoughi J [2012b]. Variation of respiratory resistance suggests optimization of 

airway caliber, IEEE Trans. Biomed. Eng. 59(8)2355–2361 

Johnson AT, Koh FC, Scott WH, Mackey KM, Chiou KYS, Rehak T [2005c]. Inhalation flow rates during strenuous 

exercise, J. Internat. Soc. Respir. Prot. 22:79-96. 

Johnson A T, Mackey KR, Scott WH, Koh FC, Chiou KYS, Phelps SJ [2005a]. Exercise performance while wearing 

a tight-fitting powered air purifying respirator with limited flow. J. Occupat. Environ. Hyg. 2(7): 368-373. 

Johnson AT, Phelps SJ, Scott Jr WH, Koh FC [2005d]. Using self-contained self-rescuers at high work rates. J. 

Internat. Soc. Respir. Prot. 22(3/4):106-111. 

Johnson AT, Scott WH, Caretti DM [2000b]. Review of recent research on respiration while wearing a 

respirator. J. Internat. Soc. Respir. Prot. 18(1):22-30. 

Johnson AT, Scott WH, Caretti DM [2000d]. Review of recent research on communications while wearing a 

respirator. J. Internat. Soc. Respir. Prot. 8:31-36. 

Johnson AT, Scott WH, Caretti DM, Danisch SG [2003]. Do respirators stress the cardiovascular system? J. 

Internat. Soc. Respir. Prot. 20(1/2):26-36. 

Johnson AT, Scott WH, Coyne KM, Koh FCS, Rebar, JE [2001b]. Telephone communications with several 

commercial respirators, Am. Indus. Hyg. Assoc. J. 62(6):685-688. 

Johnson AT, Scott WH, Coyne KM, Sahota MS, Benjamin M, Rhea PL, Martel GF, Dooly CR [1997c]. Sweat rate 

inside a full facepiece respirator. Am. Indus. Hyg. Assoc. J. 58(12):881-884. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 130 
 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

Johnson AT, Scott WH, Koh FC, Francis EB, Lopresti ER, Phelps SJ [2006]. Effects of PAPR helmet weight on 

voluntary performance time at 80-85% of maximal aerobic capacity. J. Internat. Soc. Respir. Prot. 23 (3/4):111-

118. 

Johnson AT, Scott WH, Lausted CG, Benjamin MB, Coyne KM, Sahota MS, Johnson MM [1999b]. Effect of 

respirator inspiratory resistance level on constant load treadmill work performance. Am. Indus. Hyg. Assoc. J. 

60(4):474-479. 

Johnson AT, Scott WH, Lausted CG, Coyne KM [1999a]. Comparison of treadmill exercise performance times for 

several types of respirators. J. Internat. Soc. Respir. Prot. 17:19-23. 

Johnson AT, Scott WH, Lausted CG, Coyne KM, Sahota MS, Johnson MM [2000a]. Effect of external dead 

volume on performance while wearing a respirator. Am. Indus. Hyg. Assoc. J. 61(5):678-684. 

Johnson AT, Scott WH, Lausted CG, Coyne KM, Sahota MS, Johnson MM, Yeni-Komshian G, Caretti DM [2000c]. 

Communication using a telephone while wearing a respirator, Am. Indus. Hyg. Assoc. J. 61(2):264-267. 

Johnson AT, Scott WH, Phelps SJ, Caretti DM, Koh FC [2005b]. How is respiratory comfort affected by 

respiratory resistance? J. Internat. Soc. Respir. Prot. 22:38-46. 

Johnson AT, Weiss RA, Grove C [1992a]. Respirator performance rating table for mask design. Am. Indus. Hyg. 

Assoc. J. 53(3):193-202. 

Johnston AR, Colton CE, Brosseau LM [2001]. Introduction to selection and use, in respiratory protection: a 

manual and guideline. Amer. Indus. Hyg. Assoc., Fairfax, VA, pp. 13-24. 

Jones J, McMullen MJ, Doughtery J [1987]. Toxic smoke inhalation: cyanide poisoning of fire victims. AM J 

Emerg Med 5(4):317-321. 

Karn B, Mathews HS [2007]. Nano particles without macroproblems. IEEE Spectr. 44(9): 55-58. 

Koh FC, Johnson AT, Scott WH, Phelps SJ, Francis EB, Cattungal S [2006]. The correlation between personality 

type and performance time while wearing a respirator, J. Occupat. Environ. Hyg. 3(6)317-322. 

LaTourrette T, Peterson DJ., Bartis JT, Jackson BA, Houser A [2003]. Protecting Emergency Responders, volume 

2: community views of safety and health risks and personal protection needs. Vol 2. Santa Monica, CA: RAND 

Corporation. Online at https://www.rand.org/pubs/monograph_reports/MR1646.html. 

Lausted CG, Johnson AT, Scott WH, Johnson MM, Coyne KM, Coursey DC [2006]. Maximum static inspiratory 

and expiratory pressures with different lung volumes, Biomed. Eng. 5(29), https://doi.org/10.1186/1475-925X5-29 

Mackey KRM, Johnson AT, Scott WH, Koh FC [2005]. Over breathing a loose-fitting PAPR. J. Internat. Soc. 

Respir. Prot. 22(1/2): 1-10. 

Morgan WP, Ravan PB [1985]. Prediction of distress for individuals wearing industrial respirators, Am. Indus. 

Hyg. Assoc. J. 46(7):363-368. 

MSHA [2002]. Metal and nonmetal safety and health fatal investigation report; storm exploration decline, 

Barrick Goldstrike Mines, Inc., US Mine Safety and Health Administration, Washington, DC, 

https://arlweb.msha.gov/FATALS/2002/FTL02m36&37.HTM 

NIH [2010]. What is COPD? Bethesda, MD: US Department of Health and Human Services, National Institutes of 

Health, National Heart, Lung, and Blood Institute, https://www.nhlbi.nih.gov/health-topics/copd. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 131 
 

 

 

 

 

 

CHAPTER 7 

CBRN EQUIPMENT AND THE WEARER 

NIH [2011]. What are asbestos-related lung diseases? Bethesda, MD: US Department of Health and Human 

Services, National Institues of Health, National Heart, Lung, and Blood Institute, 

https://www.nhlbi.nih.gov/health-topics/asbestos-related-lung-diseases. 

NIOSH [2017]. World trade center health program at a glance. Cincinnati, OH: U.S. Department of Health and 

Human Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, https://www.cdc.gov/wtc/pdfs/paag20170930.pdf 

Park A [2001]. Telling disease from terror. Time 158(17): 26. 

Rebar JE, Johnson AT, Russek-Cohen E, Caretti DM, Scott WH [2004]. Effect of differing facial characteristics on 

breathing resistance inside a respirator mask, J. Occupat. Environ. Hyg. 1(6):343-348. 

Saunders KB, Bali HN, Carson ER [1980]. A breathing model of the respiratory system: the controlled system, J. 

Theor. Biol. 84(1):135-161. 

Savolainen H, Kirchner N [1997]. Toxicological mechanisms of fire smoke. Internet J. Rescue Disaster Med. 1(1), 

http://ispub.com/IJRDM/1/1/5495 

Scott WH, Coyne, KM, Johnson MM, Lausted CG, Sahota M, Johnson AT [2002]. Effects of caffeine on 

performance of low intensity tasks, Percep. Motor Skills 94(2):521-532. 

Scott WH, Koh FC, Chiou KYS, Mackey KRM, Johnson AT [2008]. Quantifying energy expenditure during waterimmersion in non-trained cyclists, Biol. Eng. 1(4):281-289. 

Sumi K, Tsuchiya Y [1973]. Combustion products of polymeric materials containing nitrogen in their chemical 

structure. J. Fire Flamm. 4:15-22. 

Sutcliffe WG, Condit RH, Mansfield WG, Myers DS, Layton DW, Murphy PW [1995]. A perspective on the 

dangers of plutonium. Livermore, CA: Lawrence Livermore National Laboratory. 

Westfeld, A [2006]. Study reveals effects of ground zero toxins. Thibodaux, Louisiana: Nicholls State University, 

The Nicholls Worth. http://thenichollsworth.com/105920/uncategorized/study-reveals-effects-of-ground-zerotoxins/. 

Wikipedia [2012]. Sarin gas attack on the Tokyo subway. 

https://en.wikipedia.org/wiki/Tokyo_subway_sarin_attack 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 132 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

CHAPTER 8 – 

RESPIRATOR DECONTAMINATION 

AND DISPOSAL 

Author: Zack Mansdorf 

Decontamination is important for avoiding cross contamination, to allow for the potential reuse of 

expensive and difficult to replace equipment, and for the proper disposal of contaminated personal 

protective equipment (PPE). In every case, some level of decontamination must be performed to allow 

for the safe removal (doffing) of the protective ensemble. Decontamination approaches depend on 

many factors, including the protective ensemble used; the known or suspected chemical, biological, 

radiological, and nuclear (CBRN) agent; the available decontamination resources; and the urgency of the 

situation. Decontamination of Level A (National Fire Protection Association [NFPA] 1991) ensemble selfcontained breathing apparatus (SCBAs) is not necessary, assuming the fully encapsulating gas-tight suit is 

not breached and there is effective decontamination of the ensemble before taking off the SCBA. All 

other respiratory equipment categories and levels will need some degree of decontamination (Levels BC, NFPA 1994 Class 2 and below, National Institute of Justice Law Enforcement Response Level [NIJ LERL] 

1 and below) if exposed to a CBRN agent. Recovery and reuse will depend on the ability to demonstrate 

that the decontamination has been effective. Reuse is not permitted for Level B and C CBRN respirators 

under National Institute for Occupational Safety and Health (NIOSH) and manufacturers’ criteria if any 

liquid or vapor from a chemical warfare agent (CWA) could have contacted the respirator [3M 2009; 

NIOSH 2006]. 

There are many approaches and commercially available systems (as well as military equipment and 

approaches) for decontamination of CBRN agents. This chapter reviews the essential aspects and issues 

of CBRN agent decontamination. It does not include any discussion of commercially available 

decontamination systems and decontamination of accessory equipment used with respirators (e.g., 

communications systems, drinking systems, cameras, etc.). It will include some information on United 

States military techniques and approaches. 

What is Contamination? 

Contamination can be simply defined as the addition of an unwanted agent. It follows then that 

decontamination is the removal (or neutralization) of the unwanted agent. The contaminating agent can 

be something as benign as dirt or as difficult as an extremely hazardous agent that has permeated the 

protective ensemble. For some substances, there may be no effective decontamination procedure 

available (e.g., polychlorinated biphenyls), while for others, decontamination is simply a matter of 

cleanliness (e.g., removal of the surfacecontamination). Effective decontamination of CBRN materials 

depends on knowing the type and physical nature of the material encountered, extent of contamination, 

degree of hazard presented, and access to an effective decontamination method. 

For those situations beyond normal cleaning for hygienic purposes where contamination is likely or 

decontamination is a required precaution, the decontamination technique and efficiency should be 

determined before use of the respirator and protective clothing. This would include information and 

training supplied to the user on how to minimize the potential for contamination, the risks from 

contamination, and the decontamination procedures. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 133 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

Types of Contamination 

There are three basic categories of contamination of respirators and chemical protective clothing 

[Mansdorf 1992a]. The first is surface contamination. This is where the contaminant (e.g., dry 

particulate) does not enter the pores or molecular matrix of the protective barrier. It is simply surface 

adhesion taking place. The second category is pore contamination. This is where the contaminant enters 

the pore structure of the barrier (much like the contamination of leather by organics such as solvents, 

gasoline, etc.). The third and most difficult category is matrix contamination. This is where the 

contaminant actually permeates the molecular matrix of the protective barrier (e.g., goes into solution 

with the barrier or its ingredients). Matrix contamination is basically an artifact of permeation (diffusion 

of the contaminant through the barrier). 

Elastomeric respirator facepiece materials are subject to surface and matrix contamination, but not pore 

contamination as their surfaces are essentially non- porous. Surface contamination is usually removed 

through physical means, such as washing or brushing. Contaminants with water solubility can be 

dissolved with enhanced efficiency using agents such as emulsifiers or wetting agents (e.g., soaps and 

detergents). Water washing should be used cautiously for water reactive chemicals and solids. The 

military also uses sorbents and neutralizing agents for removal of some chemical and CWA 

contamination (e.g., M295 Individual Decontamination Kit) [USACHPPM 2008]. 

A good example of matrix contamination is the diffusion of ethylene oxide from rubber medical 

catheters after being sterilized. That is, the gaseous ethylene oxide permeates the rubber of the catheter 

in the sterilizer and then continues to outgas small quantities of ethylene oxide even when removed 

from the gas source. Hence, aeration is required to “rinse” the ethylene oxide from the rubber matrix. 

Accessory equipment for respirators such as communications systems, drinking systems, hoods, lens 

protectors, or camera systems also have the potential for contamination. Consult the manufacturer for 

specific instructions and limitations for decontamination. 

Effects of Contamination 

Surface contamination is generally not as harmful to the barrier as matrix contamination. Nevertheless, 

surface contamination can result in physical deterioration of the barrier, such as discoloration, pitting, 

cracking, or other changes. Matrix contamination can wash out additives in the barrier, such as the 

plasticizers, causing physical damage or loss of physical properties. For example, some rubbers may 

become brittle after contamination and decontamination [Coletta et al. 1988]. 

What is perhaps most important is the subsequent effects of re-exposure. Tests have shown that 

contamination of the matrix typically results in short subsequent breakthrough times and may also result 

in a greater flow or migration of the contaminant to the inside of the barrier [Forsberg and Faniadis 

1986; Perkins 1991; Schlatter 1988]. 

Even where there is no visible change to the barrier and permeation is not expected, there is still the 

potential for cross- contamination of the wearer from removal of the protective ensemble [Mansdorf 

1989]. Prevention of cross-contamination should be handled as degradation occurs, the facepiece should 

be discarded after initial decontamination. Degradation of the barrier material is the primary reason 

NIOSH Use and Limitation recommendations for CBRN-approved respirators (as a complete ensemble) 

include specific time periods for decontamination and disposal following liquid and vapor exposure to a 

CWA. These are generally based on a 30-minute vapor challenge test that runs for eight hours and a 

liquid challenge test also performed for eight hours {20015a,b]. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 134 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

A “universal precaution” like that practiced for control of contamination by blood-borne pathogens. The 

user of the protective clothing should take off (doff) that clothing in a manner that will result in the least 

likelihood of cross-contamination. This usually requires that the boots and outer gloves be removed first, 

followed by the suit (handling the inside surface for removal), followed by the respirator and inner gloves 

(from the cuffs, inside out). 

Breakthrough testing for the NIOSH approval standard for CBRN respirators using an actual 

representative CWA of sulfur mustard (HD) and Sarin (GB) is done as part of the approval process 

[Bartram et al. 2008]. This testing is described in Chapter 2. Research performed by NIOSH has 

demonstrated some permeation for certain types of facepiece elastomers. CWA permeation testing has 

been done on other polymers that are used in chemical protective clothing as well, but mostly on suit 

materials [Forsberg and Mansdorf 2007]. 

Degradation can occur when barrier materials are exposed to liquid or vapor challenges. Degradation is 

the change in the physical properties of the barrier. This can include discoloration, cracking, staining, and 

other visual indicators. It should be noted that not all degradation can be observed visually. When 

degradation occurs, the facepiece should be discarded after initial decontamination. Degradation of the 

barrier material is the primary reason NIOSH Use and Limitation for CBRN- approved respirators (as a 

complete ensemble) include specific time periods for decontamination and disposal following liquid and 

vapor exposure to a CWA. These are generally based on a 30-minute vapor challenge test that runs for 

eight hours and a liquid challenge test also performed for eight hours [NIOSH 2005a,b]. 

Evaluation of Contamination 

Tests for contamination can range from simple visual observation or use of a radiation detection device 

to relatively sophisticated chemical or biological analysis. Visual observation is appropriate if the 

contaminant does not permeate the barrier and can be visually observed (e.g., a dry pigment). For other 

materials that do not permeate the barrier, simple “swipe” testing of the surface of the barrier may be 

appropriate. The military uses a “swipe” test kit for determining certain types of contamination [Lillie et 

al. 2006]. As another example, pH paper can be used to test for contamination of the protective 

ensemble if the contaminant is acidic or basic [Mansdorf 1992a]. 

General Decontamination Approaches for Each Type of CBRN

Agent 

CWAs and Other Hazardous Chemicals 

CWAs includes nerve agents (e.g., tabun, sarin, soman), blister agents (mustard, nitrogen mustard, 

lewisite), blood agents (e.g., hydrogen cyanide, cyanogen chloride, arsine) and choking agents (e.g., 

phosgene, diphosgene) [Czerw et al. 2009]. Terrorists could also use what have been termed toxic 

industrial chemicals (TICs) in an attack. For example, chlorine has been used in some attacks in Iraq 

[Eckroade 2010]. There are many TICs that represent a significant hazard to responders, including 

cyanides, hydrogen fluoride, chlorine gas, and others. In general, materials that are gases or highly 

volatile are not as much of a decontamination problem as the liquid chemicals, which do not disperse 

with the wind or evaporate quickly, such as VX [USACHPPM 2009]. Since the range of CWAs and TICs is 

so broad, there is no single universal neutralizing agent available. Strong oxidizing or reducing liquids 

(e.g., hypochlorite, potassium permanganate, and sodium hydroxide) were originally used to 

decontaminate chemical agents, especially nerve agents, from equipment. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 135 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

Today, there are a number of military and commercial products that work for most, but not all CBRN 

agents. The manufacturers can provide the test data for evaluation. 

Biological Agents 

There are a wide variety of biological agents that span the spectrum of viruses (e.g., Zaire ebolavirus, 

which causes Ebola), bacteria (e.g., Bacillus anthracis, which causes anthrax), rickettsia (e.g., Rickettsia 

prowazekii, which causes typhus), and toxins (e.g., ricin). The threat is generally from aerosols (e.g., 

powder for anthrax spores) [Lillie et al. 2006]. If a biological agent is suspected, strong disinfecting 

solutions can be used for initial decontamination of equipment. This includes the use of sodium 

hypochlorite (household bleach) in a 1 to 10 ratio. This is effective for most, but not all, biological 

contamination with attention paid to contact time [Lillie et al. 2006]. 

Radiological Agents 

Radiological agents can be removed based on their physical and chemical nature just as non-radiological 

agents are decontaminated; however, they cannot betruly decontaminated (neutralized). The advantage 

with radiological agents is the availability of monitoring equipment to detect the level of contamination. 

Again, it is important to know the radiological agent or agents to ensure the measurement technique will 

have the appropriate sensitivity to the radiological spectrum presented (alpha, beta, or gamma). Most of 

the radiological hazards can be physically (washing with soap and water) removed since the hazard will 

probably be from particulate contamination [Lillie et al. 2006]. 

Nuclear Agents 

Response following a nuclear event would present radiological hazards from neutron- induced activity 

hazards and fission products contained principally in the fallout (particulate debris). As in the case 

of radiological agents, determination of contamination is relatively simple, provided adequate detection 

equipment is available. Scrubbing with soap and water is generally an effective initial decontamination 

technique since the majority of the contamination is from fallout [Lillie et al. 2006]. 

General Decontamination Approaches for CBRN Respirators 

As a very brief review, there are essentially four types of NIOSH-approved CBRN respirators. These are 

self-contained breathing apparatus (SCBAs), powered air-purifying respirators (PAPRs), air-purifying 

respirators (APRs), and air-purifying escape respirators (APERs). There is a detailed discussion of CBRN 

respirators in Chapter 7. SCBAs can be worn inside a fully encapsulating gas-tight suit (EPA/OSHA level A) 

or inside or outside of an EPA/OSHA level B protective suit that is not gas tight. Only SCBAs worn inside a 

fully encapsulating gas-tight suit will not require decontamination (other than normal cleaning 

procedures), provided the suit remains intact and there is no cross-contamination in removal of the 

protective ensemble. All other respirators will require decontamination unless there is confirmation that 

the area entered was not contaminated. 

The normal response to an unknown CBRN agent would be a Level A ensemble [Mansdorf 1992b]. In the 

unlikely event that there is a response with less protection than this, the respirators should be sprayed or 

brushed with a soap and water solution (or the same solution used for cleaning the protective clothing) 

to hopefully dislodge any surface contamination as a first stage. The runoff from the cleaning must be 

collected (usually piped or held in a small pool). After the outer gloves and protective suit are removed, 

the canisters from APR and PAPR respirators must be removed and cannot be decontaminated. They 

should be removed by a protected attendant (wearing the same level of protection as the respirator 

wearer or one level lower if the contaminant is known) and bagged as contaminated. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 136 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

Then, the same attendant should collect the respirator facepiece and bag it either in the same bag as the 

canisters for disposal or in a separate bag for later decontamination and testing. The military use 

transparent six-millimeter plastic bags to collect these respirators. For both the canisters and the 

respirator facepieces, the bags could then be placed into another clean transparent six-millimeter plastic 

bag (double bagging) and placed into a metal drum or otherwise handled for later decontamination or 

disposal [Lillie at al. 2006]. 

The military decontaminates and reuses their non-SCBA respirator facepieces, except when they cannot 

confirm effective decontamination. The NIOSH advice for CBRN APR respirators does not permit reuse 

after contact with a CWA (liquid or vapor) and the respirator manufacturers provide this warning in their 

instructions. Therefore, the entire respirator with canisters could be discarded after use for later disposal 

as hazardous waste. 

Decontamination Staging 

It is necessary to establish an area for decontamination either before or during the initial entry into the 

contaminated zone. Ideally, the decontamination area would be established before entry. The 

decontamination area must be sited in a “clean” location free of contamination. If this is not possible, 

contaminated personnel should initially be “washed” in their full response ensembles and transported to 

an area that is “clean.” The initial field wash (normally soap and water) must be collected either using a 

temporary ditch lined with plastic or a portable pool for later treatment of the wastewater. 

A decontamination station can range from a very simple field expedient arrangement (see Figure 8-1) to 

use of commercial or military mobile units or even the construction of semi-permanent buildings. The 

same basic principles apply in all cases. The established decontamination station must be in a clean zone 

upwind of the contaminated area; provide rinse and wash stations either by pressurized spray, shower, or 

hand application; include collection points for the response ensemble; and provide a shower area for 

personnel after decontamination. Victims should be handled in a similar fashion, with the addition of 

medical triage and potentially an isolation capability for transportation to a medical facility. 

The focus of this section is specific to the decontamination of the CBRN respirators. The rinse and wash 

solutions used will depend on the CBRN agent suspected or known to be present. The default standard is 

uncontaminated water and soap. Warm water is more effective than cold water if the capability for 

heating is present. As noted earlier, the mechanical displacement of contamination is generally effective 

using standard washing techniques for most CBRN agents [Lillie et al. 2006]. 

The general procedure is an initial rinse with water followed by an aggressive washing (using brushes) 

and a final rinse of the protective clothing ensemble. Boots should be removed first, followed by the 

outer gloves and suit, followed by the respirator, and then the inner gloves. Each should be collected by 

the attendant. The attendant should remove the canisters from the respirator or PAPR and place the 

facepiece in a normal sanitization solution. The canisters should be bagged as hazardous waste. The 

blower assembly and hoses for the PAPR should be collected separately for a determination of whether 

they could be recovered and reused. SCBAs that have been worn in a gas-tight suit should not require 

decontamination other than normal handling, unless they were inadvertently contaminated during 

removal. Level B or NFPA Class 2 protection with an SCBA worn on the outside of the protective suit 

(splash suit) would require decontamination or disposal and is not recommended for this reason. This 

also applies to the NIJ LERL 1. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 137 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

Complicating Issues in Decontamination 

There are several potential complicating issues in decontamination. Soap and water washing is the 

general approach if the contaminant is unknown. This will likely reduce contamination to allow for 

removal of the protective ensemble, but will not neutralize it or render the contamination harmless. It is 

a precautionary measure until the contaminant and decontamination technique are known. There may 

be an immediate need to enter into the contaminated zone before the decontamination station is 

completed. 

Figure 8-1. Simplified Decontamination Station. 

This scenario, while not advisable, could occur. In this case, personnel should be kept at an absolute 

minimum and kept in a relatively safe area upon return, until the decontamination station is completed. 

All wastes from the decontamination station are considered hazardous unless otherwise determined. 

This includes all decontamination solutions used and collected. If a method to measure the 

contamination is unknown, the entire protective ensemble, including respiratory protection, must be 

held as hazardous waste. Reuse of respirators of all types requires assurance that they are not 

contaminated. Therefore, the effectiveness of the decontamination procedures must be determined 

before the respirators are reused. In large responses, this could create equipment shortages. 

Summary 

All CBRN response ensembles require some level of decontamination before they can be taken off if 

exposed to a CBRN agent. This is because of the risk of user exposure and cross-contamination, to allow 

for the potential reuse of expensive and difficult to replace equipment, and for the proper disposal of 

contaminated PPE. Decontamination approaches vary widely depending on the CBRN agent 

encountered. A universal approach used until the actual CBRN agent is known is to use a soap and water 

wash before doffing the equipment. Decontamination of Level A or NFPA 1991 ensemble SCBAs is not 

necessary, assuming the fully encapsulating gas-tight suit is not breached and there is effective 

decontamination of the ensemble before removal of the SCBA. Recovery and reuse of the respirators 

will depend on the ability to demonstrate that the decontamination has been effective. Reuse is not 

permitted with Level B and C CBRN respirators under NIOSH recommendations and manufacturers’ 

criteria if a CWA is present. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 138 
 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

References 

3M [2009]. Technical data bulletin #159, recommended use of CBRN full facepiece air-purifying 

respirators. St. Paul, MN: 3M, http://multimedia.3m.com/mws/media/211122O/recommend-use-of-cbrnfull-facepiece-air-purifying-respirators.pdf?fn=TDB159(2-2009).pdf 

Bartram PW, Lindsay RS, Palya FM, Rivin D, Rodriguez A, Shuely WJ [2008]. Estimating the permeation 

resistance of nonporous barrier polymers to sulfur mustard (HD) and sarin (GB) chemical warfare agents 

using liquid simulants. Atlanta, GA: US Department of Health and Human Services, Centers for Disease 

Control and Prevention, CDC Stacks, https://stacks.cdc.gov/view/cdc/11749. 

Coletta GC, Mansdorf SZ, Berardinelli SP [1988]. Chemical protective clothing test method development: 

part II, degradation test method. Am Ind Hyg Assoc J. 49(1):26-33. 

Czerw RJ, Flynn GJ, Carpenter WB, Loftus TJ [2009]. Multiservice tactics, techniques, and procedures for 

health service support in a chemical, biological, radiological, and nuclear environment, field manual (FM) 

4-02.7 Washington, DC: Department of Defense, US Army, US Marine Corps, US Navy, US Air Force. 

Eckroade RJ [2010]. Understanding performance standards for law enforcement CBRN protective apparel. 

The Police Chief 77(7):16-19, http://www.nxtbook.com/nxtbooks/naylor/CPIM0710/#/4. 

Forsberg K, Faniadis S [1986]. The permeation of multi-component liquids through new and pre-exposed 

glove materials. Am Ind Hyg Assoc 47(3):189-193. 

Forsberg K, Mansdorf SZ [2007]. Quick selection guide to chemical protective clothing. 5th edition. New 

York: Van Nostrand Reinhold. 

Lillie SH, Kelly JM, Mattis JN, Rayburn BB [2006]. CBRN decontamination: multiservice tactics, techniques, 

and procedures for chemical, biological, radiological, and nuclear decontamination, field manual (FM) 3-

11.5. Washington, DC: Department of Defense, US Army, US Marine Corps, US Navy, US Air Force, 

http://www.dtic.mil/docs/citations/ADA523781. 

Mansdorf SZ [1989]. Chemical protective clothing use in US hazardous waste operations - observations 

and recommendations. In: Proceedings of the third Scandinavian symposium on protective clothing 

against chemicals and other health risks. Umeå, Sweden: Department of NBC Defense, Swedish Defense 

Research Institute. 

Mansdorf SZ [1992a]. Personal protective equipment decontamination for hazardous waste operations 

and emergency response. In: McBriarty J, Henry N eds. Performance of protective clothing: fourth 

volume. ASTM STP 1133. West Conshohocken, PA: American Society for Testing and Materials. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 139 
 

 

 

 

 

 

 

 

 

 

CHAPTER 8 

RESPIRATOR DECONTAMINATION AND DISPOSAL 

Mansdorf SZ [1992b]. Personal protective equipment for hazardous materials spills response. ByDesign 

37(12). 

NIOSH [2005a]. Determination of full facepiece, tight-fitting, negative-pressure, air-purifying respirator 

(APR) performance during dynamic testing against chemical agent distilled Sulfur Mustard (HD) vapor and 

liquid CBRN standard test procedure (STP). Pittsburgh, PA: US Department of Health and Human Services, 

Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/stps/pdfs/RCT-CBRN-APR-STP-0351.pdf. 

NIOSH [2005b]. Determination of full facepiece, tight-fitting, negative-pressure, air-purifying respirator 

(APR) performance during dynamic testing against chemical agent Sarin (GB) vapor CBRN standard testing 

procedure (STP). Pittsburgh, PA: US Department of Health and Human Services, Centers for Disease 

Control and Prevention, National Institute for Occupational Safety and Health, 

https://www.cdc.gov/niosh/npptl/stps/pdfs/RCT-CBRN-APR-STP-0350.pdf. 

NIOSH [2006]. List of NIOSH standard protections, cautions and limitations for approval labels. Pittsburgh, 

PA: US Department of Health and Human Services, Centers for Disease Control and Prevention, National 

Institute for Occupational Safety and Health, http://www.cdc.gov/niosh/docket/archive/pdfs/NIOSH008/0008-100106-handout_7.pdf. 

Perkins JL [1991]. Decontamination of protective clothing. Appl Occup Environ Hyg 6(1):29-35. 

Schlatter CN [1988]. Effects of water rinsing on subsequent permeation of rubber chemical protective 

gloves. In: Mansdorf SZ, Sager R, Nielsen AP, eds. Performance of protective clothing. ASTM STP 989. 

West Conshohocken, PA: American Society for Testing and Materials. 

USACHPPM [2008]. The Medical CBRN Battlebook, Technical Guide 244. Aberdeen Proving Ground, MD: 

US Department of Defense, US Army. 

USACHPPM [2009]. Safety and health guidance for mortuary affairs operations: infectious materials and 

CBRN handling, technical guide 195. Aberdeen Proving Grounds, MD: US Department of Defense, US 

Army. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 140 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

CHAPTER 9 – 

CBRN RESPIRATOR USER TRAINING 

Author: Larry Janssen 

Introduction 

The National Institute for Occupational Safety and Health (NIOSH) certification process described in 

Chapter 2 assures that chemical, biological, radiological, and nuclear (CBRN) respirators can protect users 

against a wide range of potential hazards. However, the expected level of protection cannot be achieved 

if the respirators are not used properly. Initial and ongoing training are necessary to ensure that each 

user is able to don and wear the respirator and other protective equipment while performing their 

assigned duties. Although information from several regulations and standards of practice must be 

conveyed to those trained, the ability to safely and effectively perform assigned tasks is the paramount 

goal of the training program. Because of the frequent use of CBRN respirators in combination with 

additional personal protective equipment (PPE), respiratory protection and PPE training should be 

conducted using an integrated, ensemble approach. The broad range of work activities performed by 

users of this equipment must be considered in developing an effective training program. 

Regulations and Standards 

The Occupational Safety and Health Administration (OSHA) Respiratory Protection regulation 

[Respiratory protection, 2010] has specific training requirements for respirator users. Other documents, 

including OSHA’s Hazardous Waste regulation (HAZWOPER) [Hazardous waste, 2010] and National Fire 

Protection (NFPA) standards 472 and 473 [NFPA 2008a,b] include respiratory protection among the 

competencies listed for several levels of emergency responder, and NFPA standard 1404 provides 

detailed information for training the fire service in the use of respiratory protection [NFPA 2006]. 

The OSHA Respiratory Protection regulation lists seven training topics in which respirator users must 

demonstrate knowledge: 

1. Why the respirator is necessary and how improper fit, usage, or maintenance can compromise the 

protective effect of the respirator 

2. Limitations and capabilities of the respirator 

3. How to use the respirator effectively in emergency situations, including situations in which the 

respirator malfunctions 

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

5. Procedures for maintenance and storage of the respirator 

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

respirators 

7. The general requirements of this section (1910.134) 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 141 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

Training in all these areas must be completed before a worker’s first respirator use in a work situation 

and repeated at least annually. Retraining is also required if changes in respirator type or usage make 

prior training obsolete, or if a deficiency in a worker’s knowledge or respirator use is apparent. OSHA 

does not specify a particular training method or provide assistance on how to assess workers’ knowledge 

and understanding of the training. 

In order to integrate these minimal respirator training requirements with the additional PPE and the 

duties of the workers undergoing training, the following additional topics should be also be addressed: 

8. Recognition of CBRN vs. non-CBRN respirators 

9. Specific nature of the tasks/duties to be performed while using CBRN respirators 

10. Concurrent donning and use of other protective equipment 

11. Doffing the selected ensemble, including decontamination and disposal procedures 

12. The organization’s respiratory protection program and policies, including user rights and 

responsibilities 

While not specifically required by OSHA regulations, individuals who supervise respirator use (e.g., 

incident commanders) should receive the same training as users, with additional emphasis on equipment 

selection, administrative procedures, and the recognition and resolution of problems related to 

respirator use. Those involved in purchasing or issuing respiratory protection or other PPE must also be 

familiar with the devices in use and understand why only the specified devices may be purchased. 

Substitution is not acceptable. 

Instructors 

It is implicit that those who design, deliver, and evaluate user training should have the necessary 

knowledge and skills to do so. This is not stated in OSHA’s Respiratory Protection regulation, but is 

mentioned in general terms for training employees covered by the HAZWOPER standard [Hazardous 

waste, 2010]. 

NFPA standard 1041 [NFPA 2007] describes in detail the qualifications and competencies necessary for 

fire service instructors at three levels of responsibility for preparing, delivering, and evaluating the results 

of instruction, as well as training program administration. 

Specificity 

It is critical to recognize that for every group trained, the program presented must address the 

specific respirator(s) and other PPE that will be used, as well as the tasks each person will be 

expected to perform [NFPA 2006]. 

“Generic” training materials and other programs that provide broad information not relevant to the 

tasks to be performed are not appropriate. The 12 training topics listed earlier in this chapter must be 

addressed regardless of the type of CBRN respirator chosen. However, each must be tailored to address 

special characteristics, unique training or use procedures, and the limitations of the respirator to be 

used. In some cases, these attributes may only apply to one brand or model of respirator. As such, 

manufacturers’ instructions must always be an integral part of user training materials. For example, 

different manufacturers of CBRN powered air-purifying respirators (PAPRs) may require dissimilar 

procedures for battery maintenance or verifying that their device’s flow rate is adequate. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 142 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

Only the information that applies to the specific respirator in use should be covered in training; the other 

manufacturers’ instructions are irrelevant. 

Training should be designed to impart proficiency in a desired set of skills to the recipients. Attainment 

of these goals demands not only classroom instruction, but also opportunity for demonstrations and 

extensive “hands-on” practice of each skill. Skills should be introduced and developed individually and, 

when each is mastered, combined and practiced as they will be used during a response [NFPA 2006]. 

Specifically, the goals for user training are to develop proficiency in the following skills: 

• The ability to don, use, and doff (including, if appropriate, decontamination and disposal of) the 

chosen respirator(s) and additional protective equipment 

• The ability to perform the intended tasks while wearing the protective ensemble 

• The ability to respond appropriately to unanticipated equipment malfunction or other emergencies 

Evaluation 

Evaluation of the adequacy of training should assess both the knowledge and the skills of the 

participants (i.e., their ability to perform as they were trained). The former can be accomplished using 

verbal or written assessments such as quizzes or discussion with each training recipient. The latter must 

be judged by observation of the trainees performing the procedures and tasks they were taught. This 

evaluation is best done with simulations of the intended response (e.g., victim rescue, containing and 

cleaning up a chemical release, or administering medical assistance). Of the 12 training topics listed 

earlier in this chapter, only numbers 1, 2, 6, 7, and 12 lend themselves to evaluation by knowledge 

testing alone; the remaining 7 topics must be evaluated by a combination of knowledge assessment and 

observation of performance. 

Criteria for acceptable performance must be developed prior to the training and clearly conveyed to the 

participants when training starts. Procedures and policies for retraining and reevaluating unacceptable 

performance must also be in place before training begins. Given the potentially severe consequences of 

improper respirator or PPE use in highly toxic work environments,student evaluation criteria must be 

rigorous, but fair. 

Frequency 

As noted earlier in this chapter, the minimum frequency for respiratory protection training is annually for 

organizations regulated by OSHA. The HAZWOPER regulation also calls for annual refresher training, 

including use of personal protective equipment for affected workers [Hazardous waste, 2010]. While 

NFPA 1404 specifies at least annual retraining and recertification of respirator users, it also makes 

reference to “an ongoing training program”[NFPA 2006]. The latter should be the goal of the 

organization. More frequent periodic training, as resources permit, will enhance retention of the skills 

needed for the safe use of respirators and other PPE. 

Records 

While OSHA has no specific legal requirement to keep records of respiratory protection training, it is 

advisable to keep records that include at least the following information: 

Names of the people trained 

Dates the training was conducted 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 143 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

Training materials, including handouts, outlines, manufacturer’s instructions, and a description of 

simulations and other activities 

Evaluation criteria and performance results 

As described in Chapter 5, an annual evaluation of the effectiveness of the entire respiratory protection 

program is strongly recommended. The training program should be a part of this evaluation. If changes 

to the training are needed, they should be documented in the evaluation and incorporated into the next 

training session. 

Training Program Development Template 

Because effective training programs must be “tailor made” to address the specific protective 

ensemble(s) and tasks to be performed by an organization, it is not possible to offer a universal training 

program. However, certain topics must be addressed in some way in any training program. The 12 

training topics listed earlier in this chapter serve as a useful starting point in the development of a 

training program. This section expands on the 12 topics. The suggestions are not all inclusive, but they 

will assist trainers in creating site-specific programs. It is the responsibility of individual organizations to 

completely address the training elements necessary for safe respirator use. Further, it is assumed that 

organizations that use this template have written operating procedures to address each of the elements 

of an effective respiratory protection program. 

1. Why the respirator is necessary and how improper fit, usage, or maintenance can compromise the 

protective effect of the respirator: 

a. For initial emergency response: 

i. Contaminants and concentrations will likely be unknown 

ii. Presume highly toxic/immediately dangerous to life or health (IDLH) until proven otherwise; 

maximum available protective equipment 

iii. Protective ensemble (e.g., Level A or NFPA 1991 with CBRN self- contained breathing 

apparatus [SCBA]) shown to resist penetration and provide inhalation protection against a 

wide range of chemical warfare agents and other toxins when properly selected, fitted, 

maintained, and used 

b. For known hazards (e.g., initial responders have identified and quantified the toxic materials or 

industrial use): 

i. Identify contaminant(s), describe toxic effects, relate to exposure limits if applicable 

ii. Protective ensemble has been shown to offer appropriate protection (e.g., skin, inhalation) at 

the concentrations/conditions encountered when properly selected, fitted, maintained, and 

used 

iii. Describe measures to control/reduce/eliminate hazardous exposures 

c. For all usage: 

i. All instructions and training must be carefully followed to attain protection 

ii. Greatest threats to effective protection: 

1. Removal of PPE (e.g., respirator) in contaminated atmosphere 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 144 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

2. Poorly inspected/maintained PPE 

3. Improper selection/use in atmospheres or conditions other than those specified 

2. Limitations and capabilities of the respirator: 

a. No respirator can guarantee zero exposure 

b. Describe capabilities and limitations of the specific respirator(s) to be used 

i. All respirators: 

1. Special limitations listed in the user manual and/or NIOSH approval label 

2. Introduce assigned protection factor (APF) concepts 

ii. CBRN SCBAs: 

1. Capabilities: supply breathable air, broadest 

range of inhalation protection, maximum protection (APF=10,000) 

2. Limitations: finite air supply, duration dependent on inhalation rate, weight, bulk 

iii. CBRN PAPRs 

1. Capabilities: remove specific contaminants (describe), high level of protection (APF=1,000) 

2. Limitations: atmosphere must be characterized and not IDLH, adequate oxygen must be 

present, battery limits use duration, canister/cartridge change schedule may limit use 

duration 

iv. CBRN APRs: 

1. Capabilities: remove specific contaminants (describe), lesser but still high level of 

protection (APF=50) 

2. Limitations: atmosphere must be characterized and not IDLH, adequate oxygen must be 

present, breathing resistance contributes to fatigue, canister/cartridge change schedule 

may limit use duration 

v. CBRN APERs: 

1. Capabilities: remove specific contaminants (describe) during escape only 

2. Limitations: contaminant must be one that is removed by the canister, adequate oxygen 

must be present, not for entry into contaminated atmosphere or “sheltering in place” 

3. How to use the respirator effectively in emergency situations, including situations in which the 

respirator malfunctions: 

a. Specific to respirator(s) in use 

b. Include relevant information from user manual 

c. Specific to reasonably anticipated emergency situations 

d. Describe organization’s written operating procedures for reacting to equipment failure 

e. Develop and practice drills and simulations 

4. How to inspect, put on, remove, use, and check the seals of the respirator: 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 145 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

a. Specific to respirator(s) in use 

b. Include relevant information from user instructions 

c. Describe organization’s written operating procedures on what to do if inspection reveals defects 

or if a seal cannot be achieved 

d. Explain and demonstrate user seal checks 

e. Supervise practice of these procedures 

f. Describe qualitative or quantitative fit testing procedures to be used 

5. Procedures for maintenance and storage of the respirator: 

a. Specific to respirator(s) in use 

b. Include relevant information from user manual 

c. Describe organization’s written operating procedures for maintenance and storage 

i. Responsibilities—individual and/or centralized maintenance 

ii. Location 

iii. Ensure responsible personnel learn and practice the procedures 

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

a. Respirator/PPE-related 

i. Breathing resistance 

ii. Unusual discomfort 

iii. Symptoms of heat illness 

b. Contaminant-related 

i. For known contaminants: describe signs and symptoms of exposure 

ii. For emergency response to potential terrorism: describe signs and symptoms of exposure to 

reasonably anticipated chemical warfare agents 

iii. Anxiety 

iv. Exhaustion 

c. Describe organization’s written operating procedures explaining what affected individuals and 

other users are to do if symptoms occur 

7. The general requirements of 1910.134 

8. Recognition of CBRN vs. non-CBRN respirators: 

a. Describe special characteristics and capabilities of specific CBRN respirator(s) to be used 

b. Describe CBRN labeling requirements and locations 

c. Describe organization’s written operating procedures explaining what to do if a non-CBRN device 

is found among respirators intended for CBRN response 

9. Specific nature of the tasks/duties to be performed while using CBRN respirators: 

a. Describe specific, reasonably anticipated tasks the responder group(s) being trained will perform 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 146 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

i. Initial response, containment, hazard identification 

ii. Remediation 

iii. Decontamination 

iv. Medical services 

v. Site control, law enforcement 

b. Describe organization’s written operating procedures explaining tasks to be performed 

i. What is to be done 

ii. What is not to be done 

iii. How to react to unexpected events/upset conditions 

b. Develop and practice drills and simulations 

10. Concurrent donning and use of other protective equipment: 

a. Describe the specific personal protective equipment to be used 

b. Identify capabilities and limitations of each piece of equipment 

c. Include relevant information from user instructions 

d. Describe organization’s written operating procedures for reacting to equipment failure 

e. Explain and demonstrate donning and use of each piece of equipment 

f. Explain and demonstrate donning sequence for the entire protective ensemble 

g. Supervise practice of these procedures 

h. Integrate into drills and simulations 

11. Doffing the selected ensemble, including decontamination and disposal procedures: 

a. Describe organization’s written operating procedures for decontamination 

b. Explain and demonstrate doffing sequence for the protective ensemble, including disposition of 

used components 

c. Supervise practice of these procedures 

c. Integrate into drills and simulations 

12. The organization’s respiratory protection program and policies, including user rights and 

responsibilities. 

Conclusion 

Effective and ongoing user training is necessary for the safe use of CBRN respirators. The training should 

be designed specifically for the respirator(s) and other protective equipment to be used and the work to 

be performed. Training must assure that workers not only learn the capabilities and limitations of their 

protective equipment, but that they can demonstrate the procedures and skills necessary to achieve the 

expected level of protection. 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 147 
 

 

CHAPTER 9 

CBRN RESPIRATOR USER TRAINING 

References 

Hazardous waste operations and emergency response. 29 CFR 1910.120 (2010). 

NFPA [2006]. NFPA 1404: Standard for fire service respiratory protection training. Quincy, MA: National 

Fire Protection Association. 

NFPA [2007]. NFPA 1041: Standard for fire service instructor professional qualifications. Quincy, MA: 

National Fire Protection Association. 

NFPA [2008a]. NFPA 472: Standard for Competence of responders to hazardous materials/weapons of 

mass destruction incidents. Quincy, MA: National Fire Protection Association. 

NFPA [2008b]. NFPA 473: Standard for competencies for EMS personnel responding to hazardous 

materials/ weapons of mass destruction incidents. Quincy, MA: National Fire Protection Association. 

Respiratory protection. 29 CFR 1910.134 (2010). 

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH 148 
 

 

Appendix A – 

CBRN Respirator Standards 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-1 
 

 

 

Air-Purifying Respirators (APR) 

with CBRN Protection 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-2 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Search NIOSH | NIOSH Home | NIOSH Topics | Site Index | Databases and Information Resources | NIOSH Products | Contact Us 

Statement of Standard for Chemical, Biological, Radiological, and 

Nuclear (CRBN) Full Facepiece Air Purifying Respirator (APR) 

NPPTL Home | C ontact | Site Index 

March 7, 2003 

Revision 1; March 17, 2003 

Revision 2; April 4, 2003 

Fig. 1 Updated; January 30, 2004 

1.0 Purpose: 

The purpose of this standard is to specify minimum requirements to determine the effectiveness of full facepiece air purifying respirators (APR) 

used during entry into chemical, biological, radiological, and nuclear (CBRN) atmospheres not immediately dangerous to life or health. The 

respirator must meet the minimum requirements identified in the following Paragraphs: 

• Paragraph 2.0, Requirements Specified in Title 42 Code of Federal Regulations (CFR), Part 84 applicable paragraphs, 

• Paragraph 3.0, Requirements based on existing national and international standards, 

• Paragraph 4.0, Special requirements for CBRN use. 

2.0 Title 42 Code of Federal Regulations (CFR), Part 84: 

The following paragraphs of 42 CFR, Part 84 are applicable: 

2.1 42 CFR, Part 84, Subparts A, B, D, E, F, and G: 

Subpart A: General Provisions 

Subpart B: Application for Approval 

Subpart D: Approval and 

Disapproval Subpart E: Quality 

Control 

Subpart F: Classification of Approved Respirators 

Subpart G: General Construction and Performance 

2.2 42 CFR, Part 84, Subpart I; the following paragraphs apply: 

84.110 Gas Masks; description, paragraphs a(1), a(2), and (b) 

84.111 Gas Masks; required components 

84.112 Canisters and cartridges in parallel; resistance requirements 

84.113 Canisters and cartridges; color and markings; requirements 

84.114 Filters used with canisters and cartridges; location; replacement 

84.115 Breathing tubes; minimum requirements 

84.116 Harnesses; installation and construction; minimum requirements 

84.117 Gas mask containers; minimum requirements 

84.118 Half-mask facepieces, full facepieces, and mouthpieces; fit; minimum requirements, paragraphs a(1), a(2), (b), and (e) 

84.119 Facepieces; eyepieces; minimum requirements 

84.120 Inhalation and exhalation valves; minimum requirements 

84.121 Head harnesses; minimum requirements 

84.123 Exhalation valve leakage test 

2.3 42 CFR, Part 84, Subpart K; the following paragraphs apply: 

84.170 Non-powered air purifying particulate respirators; description 

84.179 Non-powered air purifying particulate respirators; filter identification 

84.181 Non-powered air purifying particulate filter efficiency 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-3 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.0 Requirements Based on Existing National and International Standards: 

3.1 Mechanical Connector: 

The interface between the canister and the facepiece or respirator system shall use a standard Rd 40 X 1/7 thread in accordance with Figure 1 (NIOSH 

CBRN Full Facepiece APR Mechanical Connector and Gasket). The canister shall be readily replaceable without the use of special tools. For respirators 

where the canister is attached directly to the facepiece, i.e. respirator mounted, a single interface connector thread shall be located on the facepiece. 

The interface connector on the facepiece shall be the internal thread and gaske sealing gland. The canister shall use the external thread. 

For respirators where the canister is not directly attached to the facepiece, i.e. not respirator mounted, an internal thread and gasket sealing 

gland connector complying with Figure 1 must be securely attached to a harness system to provide strain relief between the canister and the 

remaining respirator system. For respirator systems where the canister is not respirator mounted, multiple canister assemblies are permitted. 

3.2 Gasket, Mechanical Connector: 

The dimensions for the interface connector gasket shall be: outside diameter 37.5 mm minimum, inside diameter 28.5 mm maximum, minimum 

thickness 1.55 mm as illustrated in Figure 1. The gasket material shall be ethylene propylene diene monomer, EPDM, or equivalent meeting the 

physical and chemical properties of Table 1 (Rubber Gasket Physical and Chemical Properties) when tested in accordance with Table 2 (Gasket Tests, 

Specimens and Test Methods). The manufacturer is required to provide data indicating compliance with the requirements of Table 1 and 2. Agent 

permeation data is not required for EPDM gasket material meeting all other properties of Table 1. For gasket material other than EPDM material 

samples must be tested to the agent permeation requirements. 

3.3 Breathing Resistance, Canister: 

In addition to the resistance to airflow determined by paragraph 3.5, Breathing Resistance, the canister resistance to inhalation airflow shall be less 

than or equal to 50 mm water column when tested at 85 liters per minute continuous air flow. 

Table 1: Rubber Gasket Physical and Chemical Properties 

Property Units Unaged 

Minimum 

Unaged 

Maximum 

Aged 

Minimum 

Aged 

Maximum 

Tensile Strength Mpa 

(psi) 8.3 (1200) --- 6.9 (1000) ---

Ultimate elongation Percent 

(%) 350 --- 300 ---

Tensile set at 300% elongation Percent 

(%) --- 25 --- 25 

Tensile stress at 200% elongation Mpa 

(psi) 3.4 (500) --- 3.4(500) ---

Tear resistance Either Die B or Die C (1) kN/m 

(lbf/in) 21.9 (125) --- 21.9 (125) ---

Durometer hardness (Shore “A”) --- 55 75 --- ---

Compression set 22 hrs. at 68° C Percent 

(%) --- 25 --- ---

Impact resilience 

Percent 

(%) 35 --- --- ---

Agent permeation 

HD, Mustard & GB, Sarin (2) 

Minutes 

Minutes 

360 

360 --- --- ---

Low temperature brittleness at minus 51° C --- Pass --- --- ---

(1) Test specimens shall be cut from Die B or Die C. Test specimens shall not be a mixture of Die specimens. See Table 2: Tear Resistance Method 

ASTM 624 D. 

(2) The applicant shall submit agent permeation data on materials that are not classified as EPDM. Rubber material formulations that are 51% or greater in 

EPDM classifies the material as EPDM. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-4 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 2: Gasket Tests, Specimens and Test Methods 

Property 

Specimen 

Total Method 

Unaged Heat Aged (1) Oxygen aged (2) 

Tensile strength Ultimate 

elongation Tensile stress 

at 200% elongation 

Cut one specimen 

from each of three 

slabs. 

Cut one specimen 

from each of three 

slabs. 

Cut one specimen 

from each of three 

slabs. 

9 ASTM D 412 

Tensile set at 300% 

elongation 

Cut one specimen 

from each of three 

slabs. 

Cut one specimen 

from each of three 

slabs. 

Cut one specimen 

from each of three 

slabs. 

9 ASTM D 412 

Tear resistance, Either 

Die B or Die C 

Cut one specimen 

from each of three 

slabs/buttons. 

Cut one specimen 

from each of three 

slabs. 

Cut one specimen 

from each of three 

slabs. 

9 ASTM D 624 

Low temperature 

Brittleness at 

–51° 

Cut one specimen 

from each of five 

slabs. 

None None 5 ASTM D 746 

Durometer hardness 

(Shore “A”) 

Cut one specimen 

from each of three 

slabs. 

None None 3 ASTM D 

2240 

Compression set (3) Three test buttons. None None 3 ASTM D 395 

Impact resilience (3) Three test buttons. None None 3 ASTM D 

2632 

Agent permeation (4) (5) 

Sarin (GB) and Sulfur 

Mustard (HD) 

Cut two specimens 

from each of six test 

slabs. Six specimens 

per agent. 

None None 12 MIL-STD-282 

Method 208 

Method 209 

(1) Heat Aging. The specimens selected for heat aging shall be aged in an air oven at a temperature of 158° F +/-7°F (70°C -/+ 2°C) for a 

continuous period of 24 hours as prescribed in ASTM D 573. 

(2) Oxygen Aging. Specimens shall be aged in an oxygen environment in accordance with ASTM D 572 for 72 hours. (3) 

Same test buttons shall be used for impact resilience and compression set in that order. 

(4) If gasket material is not EPDM, applicant shall submit permeation test data for gasket material along with six test slabs for Agent Permeation Test. 

(5) Test specimens shall be fabricated in accordance with ASTM D 3182 from material of the same formulation that will be used during regular 

production of the respirator. The test specimens shall have a cure equivalent to that of the regular production gaskets. The thickness of the test 

specimens shall be the minimum gasket thickness specified by the applicants design specification. Any finish or treatment, applied to the finished 

gasket, shall be applied to the test specimens. 

3.4 Dimensions and Weight, Respirator Mounted (Chin Style) Canister: 

The maximumweight of a respirator mounted (chin style) canister shall be 500 grams. The maximum size of a respirator mounted (chin style) 

canister shall be such that the canister shall pass through a 5-inch diameter opening with the threaded connector perpendicular to the 5-inch 

diameter opening. 

3.5 Breathing Resistance: 

Resistance to air flow shall be measured in the facepiece of a CBRN air purifying respirator mounted on a test fixture with air flowing at 

a continuous rate of 85 liters per minute both before and after each gas service life bench test. The maximum allowable air resistance to air 

flow is as follows: 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-5 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Chin Style Non Facepiece Mounted 

Inhalation: Initial 65 mm H2O 70 mm H2O 

Final (1) 80 mm H2O 85 mm H2O 

Exhalation: 20 mm H2O 20 mm H2O 

(1) Measured at end of service life. 

3.6 Field of View: 

The full facepiece CBRN APR shall obtain a Visual Field Score (VFS) of 90 or greater. The VFS shall be obtained by using a medium size respirator 

or equivalent that is sized to fit the Head Form described in Figure 14 of EN 136, Respiratory protective devices – Full face masks – 

Requirements, testing, marking; January 1998 or equivalent. 

The VFS is determined by using a VFS grid (Dots on visual field) as defined in the American Medical Association Guides to the 

Evaluation of Permanent Impairment, 5th Edition (2000) that is overlaid on the diagram of the visual field plot obtained using the 

spherical shell of EN 136 apertometer or equivalent. The VFS score is the average of three fittings of the same respirator on the 

specified head form. 

3.7 Lens Material Haze, Luminous Transmittance and Abrasion Resistance: 

3.7.1 Haze: The haze value of the primary lens material shall be 3% or less when tested in accordance with ASTM D 1003-00. 

3.7.2 Luminous Transmittance: The luminous transmittance value of the primary lens 

material shall be 88% or greater when tested in accordance with 

ASTM D 1003-00. 

3.7.3 Abrasion Resistance: The haze and luminous transmittance of the primary lens material shall be determined in accordance with ASTM D 1003-

00 before and after subjecting the lens material to the abrasion test. The abrasion test shall be conducted in accordance with ASTM D 1044-99 

using a CS10F calibrase wheel at a minimum of 70 revolutions under a 500-gram weight. After subjecting the lens material to the abrasion test, 

remove the residue fromthe test specimens in accordance with ASTM D 1044-99 or by using a cleaning method recommended by the applicant. 

After the residue is removed from the test specimens, the test specimens shall not exhibit an increase of haze greater than 4% and a decrease of 

luminous transmittance greater than 4%. 

3.7.4 The test specimens shall be the flat four (4) inch (102mm) square version as prescribed in ASTM D 1044-99 and shall have the same nominal 

thickness and within the tolerance range as the primary lens of the CBRN APR. The test specimens shall be subjected to the same coating process 

and any other processes, as the primary lens would be under normal production conditions. A total of 6 specimens shall be furnished to NIOSH for 

certification testing, three pre-abrasion specimens and three specimens after being tested for abrasion in accordance with ASTM D-1044-99 

3.8 Carbon Dioxide: 

The maximum allowable average inhaled carbon dioxide concentration shall be less than or equal to 1 percent, measured at the mouth, while the 

respirator is mounted on a dummy head operated by a breathing machine. The breathing rate will be 14.5 respirations per minute with a minute 

volume of 10.5 liters. Tests will be conducted at ambient temperature of 25 ± 5°C. A concentration of 5 percent carbon dioxide in air will be exhaled 

into the facepiece. The minimum allowable oxygen concentration shall be 19.5 percent. NIOSH Test Procedure RCT-APR-STP-0064 is used for Carbon 

Dioxide Testing. 

3.9 Hydration: 

For CBRN APR respirators equipped with a hydration facility, the CBRN APR respirator shall meet all requirements of the CBRN APR standard with 

the hydration facility in place. Dry drinking tube valves, valve seats, or seals will be subjected to a suction of 75mm water column height while in a 

normal operating position. Leakage between the valve and the valve seat shall not exceed 30 milliliters per minute. NIOSH Test Procedure RCT-APRSTP-0014 is used for hydration facility leakage. 

3.10 Tolerance Analysis: 

The applicant w provide a tolerance analysis of the mechanical connector, canister thread and gasket identified in Paragraphs 3.1 

Mechanical Connector and 3.2 Gasket, Mechanical Connector demonstrating the applicant’s canister design will contact and seal on the gasket 

surface area defined by the 37.5mm minimum outside diameter and the 28.5 maximum inside diameter under all tolerance conditions. 

3.11 Practical Performance (Modified Laboratory Protection Level Test): 

A modified laboratory protection level test (LRPL) shall be performed using respirators fitted with a canister weighted to 500 grams and sized to the 

maximum permissible dimensions of Paragraph 3.4 Dimensions and Weight, Respirator Mounted (Chin Style) Canister. A minimum of eight 

respirators shall be tested to fulfill the small, medium, and large designations of facial size – 2 small, 4 medium, and 2 large. The measured 

laboratory respiratory protection level (LRPL) for each full facepiece, air purifying respirator shall be 2000, when the APR facepiece is tested in an 

atmosphere containing 20-40 mg/m3 corn oil aerosol of a mass median aerodynamic diameter of 0.4 to 0.6 micrometers. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-6 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.0 Special CBRN Requirements: 

4.1 Canister Test Challenge and Test Breakthrough Concentrations: 

The gas/vapor test challenges and breakthrough concentrations shown in Table 3: Canister Challenge, Breakthrough Concentrations, and Canister 

Efficiency shall be used to establish the canister service life: 

Table 3: Canister Test Challenge and Test Breakthrough Concentrations 

Test Concentration (ppm) Breakthrough Concentration (ppm) 

Ammonia 2500 12.5 

Cyanogen Chloride 300 2 

Cyclohexane 2600 10 

Formaldehyde 500 1 

Hydrogen Cyanide 940 4.7(1) 

Hydrogen Sulfide 1000 5.0 

Nitrogen Dioxide 200 1 ppm NO2 or 25 ppm NO(2) 

Phosgene 250 1.25 

Phosphine 300 0.3 

Sulfur Dioxide 1500 5 

(1) Sum of HCN and C2N2. 

(2) Nitrogen Dioxide breakthrough is monitored for both NO2 and NO. The breakthrough is determined by which quantity, NO2 or NO, reaches 

breakthrough first. 

4.2 Service Life: 

The applicant shall specify a minimum service life as part of the application for certification. For less than a 60 minute service life, applications 

shall be identified in 15-minute intervals (15 minutes, 30 minutes, 45 minutes). For a service life of 60 minutes or greater, applications shall be 

identified in 30-minute intervals (60 minutes, 90 minutes, 120 minutes). Gas life tests are performed at room temperature, 25±5° C; 25±5 

percent relative humidity; and 80 + 5 percent relative humidity. Three canisters will be tested at each specified humidity with a flow rate of 64 

liters per minute, continuous flow. Tests will be conducted to the minimumspecified service time. The canisters shall meet or exceed the 

specified service times without exceeding the identified breakthrough concentrations in Table 3. Gas testing shall be performed following 

environmental conditioning and rough handling. 

4.3 Particulate/Aerosol Canister: 

The canister shall meet the requirements of a P100 particulate filter in accordance with 

42 CFR, Part 84, paragraphs 84.170, 84.179, and 84.181. 

4.4 Service Life Testing, High Flow: 

Each canister shall provide a minimum service life of 5 minutes when tested at a flow rate of 100 liters per minute, 50±5 percent relative 

humidity and 25±5° C for each of the gases/vapors identified in Paragraph 4.1, Canister Test Challenge and Test Breakthrough Concentrations. 

4.5 Low Temperature/Fogging: 

The respirator shall demonstrate an average Visual Acuity Score (VAS) of greater or equal to 75 points for all measurements of acuity. The 

respirator shall be cold soaked and tested in an environmental chamber at minus 21° C for four (4) hours. The wearer shall not experience 

undue discomfort because of restrictions to breathing or other physical or chemical changes to the respirator. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-7 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.6 Communications: 

Communication requirements are based upon performance using a Modified Rhyme Test (MRT). The communications requirement is met if 

the overall performance rating is greater than or equal to seventy (70) percent. The MRT will be performed with a steady background 

noise of 60 dBA consisting of a broadband “pink” noise. The distance between the listeners and speakers shall be 3 meters. 

4.7 Chemical Agent Permeation and Penetration Resistance Against Distilled Sulfur 

Mustard (HD) and Sarin (GB) Agent Requirement: 

The air purifying respirator system, including all components and accessories shall resist the permeation and penetration of Distilled 

Sulfur Mustard (HD) and Sarin (GB) chemical agents when tested on an upper-torso manikin connected to a breathing machine operating 

at an air flow rate of 40 liters per minute (L/min), 36 respirations per minute, 1.1 liters tidal volume. 

Test requirements for Distilled Sulfur Mustard (HD) are shown in Table 4: 

Table 4: Vapor-Liquid Sequential Challenge of APR with Distilled Sulfur Mustard (HD) 

Agent Challenge 

Concentration 

Duration of 

Challenge 

(min) 

Breathing 

Machine 

Airflow Rate 

(L/min) 

Maximum 

Peak 

Excursion 

(mg/m3

) 

Maximum Breakthrough 

(concentration integrated over 

minimum service life)(mgmin/m3

) 

Number 

of 

Systems 

Tested 

Minimum 

Service 

Life 

(hours) 

HD-Vapor 50 mg/m3(1) 30 40 0.30(3) 3.0(4) 3 8(6) 

HD-Liquid 0.43 to 0.86 

ml(1)(2)(5) 

120 40 0.30(3) 3.0(4) 3 2 

(1) Vapor challenge concentration will start immediately after the test chamber has been sealed. Minimum Service Life for liquid exposure starts after the 

first liquid drop is applied. 

(2) Liquid volume dependent on accessories used with the respirator. Minimum volume is 0.43 ml based on the respirator and single respirator mounted 

canister. 

(3) Three consecutive sequential test data points at or exceeding 0.3 mg/m3 will collectively constitute a failure where each test value is based on a detector 

sample time of approximately 2 minutes. 

(4) The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of the test. (5) Liquid 

agent is applied to respirator at hour 6 of the test cycle. 

(6) The test period begins upon initial generation of vapor concentration and ends at 8 hours. 

Test requirements for Sarin (GB) agent are shown in Table 5: 

Table 5: Vapor Challenge of APR with Sarin (GB) 

Challenge 

Concentration 

Vapor 

Concentration 

(mg/m3

) 

Vapor 

Challenge 

Time 

(minutes) 

Breathing 

Machine 

Airflow 

Rate(L/min) 

Maximum 

Peak 

Excursion 

mg/m3 

Maximum 

Breakthrough 

(concentration 

integrated over 

minimum service 

life)(mg-min/m3) 

Number of 

Systems 

Tested 

Minimum 

Service 

Life (hours) 

GB 210(1) 30 40 0.044(3) 1.05(4) 3 8(2) 

(1) The vapor challenge concentration generation will be initiated immediately after test chamber has been sealed. (2) The 

test period begins upon initial generation of vapor concentration and ends at 8 hours. 

(3) Three consecutive sequential test data points at or exceeding 0.044 mg/m3 will collectively constitute a failure where each test value is based on a 

detector sample time of approximately 2 minutes. 

(4) The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of the test. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-8 
 

 

 

 

 

 

 

 

 

 

 

 

4.8 Laboratory Respiratory Protection Level (LRPL) Test Requirement: 

The measured laboratory respiratory protection level (LRPL) for each full facepiece, air purifying respirator shall be 2000, when the APR facepiece is 

tested in an atmosphere containing 20-40 mg/m3 corn oil aerosol of a mass median aerodynamic diameter of 0.4 to 0.6 micrometers. 

4.9 Environmental Conditioning (transportability, temperature range, 

survivability): 

Environmental conditioning shall be performed in accordance with Table 6: 

Table 6: Environmental Conditioning 

Test Test Method Test Condition Duration 

Hot 

Diurnal 

Mil-Std-81°F; Method 501.4; 

Table 501.4-II;Hot-Induced 

Conditions 

Diurnal Cycle, 35°C (950F) -71°C 

(160°F); 

3 Weeks 

Cold 

Constant 

Mil-Std-81°F, Method 502.4; Basic Cold (C1), -32°C (-95°F); 

Constant 

3 Days 

Humidity Mil-Std-810E, 507.3; Method 

507.3; Table 507.3-II 

Natural Cycle, Cycle 1, Diurnal Cycle, 

31°C (880F) RH 88% -41°C (105°F) RH 

59% 

5 Days, Quick Look 

Vibration Mil-Std-810F, 514.5 US Highway Vibration, Unrestrained 

Figure 514.5C-1 

12 Hours/Axis, 3 Axis;Total 

Duration =36 Hours, 

equivalent to 

12,000 miles 

Drop 3 foot drop onto bare concrete 

surface 

Canister only; In individual canister 

packaging container 

1 drop/filter on one of the 3 

axes. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-9 
 

 

 

 

 

 

 

 

 

4.10 Test Sequence and Quantity: 

Testing of the CBRN APR system and canisters shall follow Table 7: 

Table 7: Test Sequence and Quantity 

Test 

Order 

42 CFR 

Testing 

Human 

Factors 

Service 

Life, 

100 lpm 

Service 

Life Testing, 

64 lpm 

flow 

Particulate 

Canister 

Degradation 

Penetration 

and 

Permeation 

Testing 

Efficiency 

Particulate 

Canister 

LRPL 

Test 

Qty 3 APR 

systems; 

3 exhalation 

valve assy. 

9 APR 

Systems, 

6 lens 

samples 

30 canisters 54 canisters 6 canisters 6 APR 

systems (1) 

20 

canisters 

25 

to 

38 

systems 

1. Breathing 

Tube, 

84.115 

Para.2.2 

Commo. 

Para. 4.6 

Hot 

Diurnal 

Para. 4.9 

Hot 

Diurnal 

Para. 4.9 

Hot 

Diurnal 

Para. 4.9 

Hot 

Diurnal 

Para. 4.9 

Filter 

Efficiency 

84.181 

LRPL Para. 

4.8 

2. Facepieces; 

eyepieces 

minimum 

requirement, 

84.119 

Para.2.2 

Low 

Temperature 

Fogging Para. 

4.5 

Cold 

Constant 

Para. 4.9 

Cold 

Constant 

Para. 4.9 

Cold 

Constant 

Para. 4.9 

Cold 

Constant 

Para. 4.9 

Cold 

Constant 

Para. 4.9 

Practical 

Performance 

Test Para.3.11 

3. Canister 

in Parallel 

Resistance, 

84.112 /.122 

Para.2.2 

Facepiece 

Resistance 

Para. 3.3 

Humidity 

Para. 4.9 

Humidity 

Para. 4.9 

Humidity 

Para. 4.9 

Humidity 

Para. 4.9 

Humidity 

Para. 4.9 

Humidity 

Para. 4.9 

4. Exhalation 

valve 

leakage 

test, 84.123 

Para.2.2 

Field 

of View 

Para. 3.6 

Transportation/ 

Vibration 

Para. 4.9 

Transportation/ 

Vibration 

Para. 4.9 

Transportation/ 

Vibration 

Para. 4.9 

Transportation/ 

Vibration 

Para. 4.9 

Transportation/ 

Vibration 

Para. 4.9 

5. Hydration 

84.63(a) 

(c)(d) 

Para.3.9 

Haze, 

Transmittance, 

Abrasion 

Para. 3.7 

Drop 

Para. 4.9(2) 

Drop 

Para. 4.9(2) 

Drop 

Para. 4.9(2) 

Drop 

Para. 4.9(2) 

Drop 

Para. 4.9(2) 

6. Determine 

CO2 levels 

84.63(b) 

(c)(d) 

Para.3.8 

Tolerance 

Analysis 

Para. 3.10 

Service 

Life 

100 lpm 

Para. 4.4 

Initial 

Breathing 

Resistance 

Para. 3.5 

Canister 

Breathing 

Resistance 

Para. 3.3 

System 

Testing 

Para. 4.7 

Filter 

Efficiency 

84.181 

7. Service 

Life Testing, 

Less 

Cyclohexane, 

64 lpm 

Para. 4.2 

Service Life 

Cyclohexane 

Para. 4.2 

8. 

Final 

Breathing 

Resistance 

Para. 3.5 

DOP 

Testing 

84.181 

9. 

Final 

Breathing 

Resistance 

Para. 3.5 

(1) A total six systems tests are performed, 3 GB and 3 HD. Two systems tests, 1 GB and 1 HD, are performed prior to Para. 4.9 Environmental 

Conditioning. Four systems tests, 2 GB and 2 HD, are performed after Para. 4.9 Environmental Conditioning. (2) 

The Drop Test is performed on the canister only, in the minimum manufacturer ’s recommended packaging. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-10 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.0 Quality Assurance Requirements: 

5.1 Quality Control Plan: 

Respirators submitted for CBRN air purifying respirator approval shall be accompanied by a complete quality control plan meeting the requirements of 

Subpart # of 42 CFR, Part 84. 

5.2 Sampling/Test/Inspection Plan: 

The applicant shall specify a sampling/test/inspection plan for respirator parts and materials to ensure the construction and performance requirements of 

this standard are established through the manufacturing process. As a minimum, specific attributes to be addressed are: 

a). Materials of construction used for respirator parts that form a barrier between the user and ambient air. b). Integrity of 

mechanical seals that comprise a barrier between the user and ambient air. 

c). Final performance quality control tests on complete canisters demonstrating compliance with the gas life and particulate filter requirements of 

this standard. 

d). Conformance with mechanical dimensions of respirator to canister connecting thread. 

e). Conformance with mechanical dimensions of respirator to canister sealing gland including length of threads, gasket seating dimensions, and 

configuration. 

f). Conformance with material properties, dimensional and hardness requirements of the respirator to canister gasket. 

6.0 General Requirements: 

In addition to the requirements of 42 CFR, Subpart G – General Construction and Performance Requirements, the following requirements 

apply: 

Prior to making or filing any application for approval or modification of approval, the applicant shall conduct, or cause to be conducted, examinations, 

inspections, and tests of respirator performance, which are equal to or exceed the severity of those prescribed in the standard. Paragraph 4.7 Systems 

Tests are excluded from this requirement. NIOSH CBRN Full Facepiece APR Mechanical Connector and Gasket Drawing from Revision 3 (April 3, 2007) to 

Revision 4 (August 30, 2007). 

Page last updated: January 5, 2011 

Page last reviewed: June 20, 2004 

Content Source: National Institute for Occupational Safety and Health (NIOSH) 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-11 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DEPARTMENT OF HEALTH & HUMAN SERVICES Public Health Service 

Centers for Disease Control 

and Prevention (CDC) 

National Institute for Occupational 

Safety and Health (NIOSH) 

National Personal Protective 

Technology Laboratory (NPPTL) 

P.O. Box 18070 

Pittsburgh, PA 15236-0070 

Phone: 412-386-5200 

Fax: 412-386-4089 

August 30, 2007 

LETTER TO ALL MANUFACTURERS 

SUBJECT: Incorporation of the NIOSH CBRN Full Facepiece APR Mechanical Connector and Gasket 

drawing Revision 4, Dated 09 July 2007, into the Statement of Standard for Chemical, Biological, 

Radiological, and Nuclear (CBRN) Full Facepiece Air-Purifying Respirator (APR), Revision 2; April 4, 

2003 

The purpose of this letter is to inform all manufacturers that Revision 4 of the NIOSH CBRN Full 

Facepeice APR Mechanical Connector and Gasket drawing, dated 09 July 2007, has been 

incorporated into the Statement of Standard for Chemical, Biological, Radiological, and Nuclear 

(CBRN) Full Facepiece Air-Purifying Respirator, Revision 2; April 4, 2003 as Figure 1. This letter 

serves as a notification that all previous drawing revisions used as Figure 1 are obsolete and are no 

longer valid. Revision 4 may be downloaded from the following webpage: 

http://www.cdc.gov/niosh/npptl/resources/pressrel/letters/lttr-083007.html 

NIOSH CBRN APR approvals issued prior to the date of this letter remain NIOSH certified and 

reevaluation is not required. New or pending applications submitted for NIOSH CBRN APR 

certification must meet the requirements of Revision 4. 

The subject drawing was updated in response to questions concerning the dimensioning of 

Revision 3 (Letter To All Manufacturers, NIOSH/NPPTL, April 5, 2007, Subject: Update to the 

NIOSH CBRN Full Facepiece APR Mechanical Connector and Gasket Drawing from Revision 2 

(January 9, 2004) to Revision 3 (April 3, 2007) 

http://www.cdc.gov/niosh/npptl/resources/pressrel/letters/lttr-040307.html). The NIOSH/NPPTL 

received specific comments from manufacturers regarding Revision 3 and they were considered in 

the development of Revision 4. 

The modifications to the drawing are as follows: 

x Part A: The absolute maximum, canister air-outlet, diameter was increased from 34.0 mm to 

34.5 mm. This enhances the flexibility of the design especially with thinner walled plastic 

canisters. 

x Part A: The one degree boundary was added so that no canister cross-sectional back face 

protrudes beyond the marked boundary to avoid interference with a facepiece 

component. For ease of measurement, a definitive location for the dimension was moved 

to the end of the Thread Runout feature. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-12 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 2 – Letter to All Manufacturers 

x Part A: The Minimum Thread Runout was increased from 15.00 mm to 15.25 mm to 

enhance sealing with the internal thread component of the facepiece. Also, for the 

same reason, the minimum Effective Thread Length was increased from 13.72 mm to 

14 mm. 

x Part A: The dimension of the bend radius (2.0 Bend R) at the intersection between the 

thread neck and the canister back face was removed because it was design restrictive to 

the manufacturers. 

x Part B: The connector depth will range from 7.00 mm to 14.00 mm. This allows the depth 

measurement to remain consistent for all connectors and eliminates the need for Option 

B1 and B2 (Shorter and Longer Internal Thread Connector). All measurements will now be 

taken from the outer edge of the connector to the gasket surface. 

x Part B & C: The maximum tolerance on the gasket undercut height and gasket thickness 

has been removed, and it is left to the discretion of the manufacturer to produce a gasket 

that fits and is positively retained in the undercut. The connector depth measurement is 

defined from the outer edge of the connector to the gasket surface, thus controlling the 

thread engagement. 

x Part D: The height of the thread (t1) is a reference dimension and is indicated with 

parenthesis. 

Any questions concerning this letter or the revised drawing should be directed to the NPPTL Policy 

and Standards Development Branch at 412-386-5200. 

Sincerely, 

Jonathan V. Szalajda 

Branch Chief, Policy and Standards Development 

National Personal Protective Technology Laboratory 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-13 
APPENDIX A - CBRN RESPIRATOR STANDARDS | A-14
APPENDIX A - CBRN RESPIRATOR STANDARDS | A-15
APPENDIX A - CBRN RESPIRATOR STANDARDS | A-16
 

 

 

Powered Air-Purifying Respirators (PAPR) 

with CBRN Protection 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-17 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Statement of Standard for Chemical, Biological, Radiological, and Nuclear 

(CBRN) Powered Air-Purifying Respirators (PAPR) 

October 6, 2006 

The Chemical, Biological, Radiological, and Nuclear (CBRN) Powered Air-Purifying Respirator 

(PAPR) must meet the following minimum performance requirements: 

(a) PAPR performance criteria from NIOSH 42 CFR Part 84, to include as applicable: 

Test # Title 

1 Initial DOP - HE protection (if applicable) 

3 Exhalation resistance with blower off (tight fitting) 

4 Exhalation valve leakage (if applicable) 

5/5A/6 IAA fit test 

7 Inhalation resistance with blower off (tight fitting) 

12 PAPR Airflow* 

25 Silica Dust+ 

30 Sound Level (if applicable) 

33-48 or 62 Gas and Vapor (as applicable) 

60 ESLI visibility (if applicable) 

61 ESLI damage resistance (if applicable) 

* 115 liters per min (Lpm) for tight-fitting, 170 Lpm for loose-fitting 

+ CBRN Canister/Cartridge evaluated in Silica Dust test 

(b) Special tests under NIOSH 42 CFR Part 84.63(c) 

(1) Durability conditioning 

(2) Chemical agent permeation and penetration resistance against Distilled Sulfur 

Mustard (HD) and Sarin (GB) 

(3) Laboratory Respirator Protection Level (LRPL) 

(4) Canister test challenge and test breakthrough concentrations 

1.0 Durability conditioning (CBRN tight-fitting PAPR only) (Reference STP CBRN0311) 

1.1 Respirator containers; minimum requirements 

1.1.1 Required packaging configuration (minimum packaging configuration): The 

CBRN tight-fitting PAPR and the required components will be subjected to the 

environmental and transportation portions of the 

durability conditioning in the manufacturer specified minimum packaging 

configuration. The canisters will also be subjected to an additional rough handling 

drop test in its designated minimum packaging configuration. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-18 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.1.2 The minimum packaging configuration is the protective packaging configuration 

that the end user* will store or maintain the CBRN tight-fitting PAPR and the 

required components inside after it has been issued for immediate use. The user 

instructions (UI) will identify the minimum packaging configuration and will direct 

the end user how to store or maintain the CBRN tight-fitting PAPR and the 

required components 

inside the manufacturer specified minimum packaging configuration while in the 

possession of the end user. The same minimum packaging configuration identified 

in the UI will encase the CBRN tight-fitting PAPR and the components when NIOSH 

performs the durability conditioning. The type of the minimum packaging 

configuration, if any, is left to the discretion of the manufacturer. Examples of 

common minimum packaging configurations are mask carriers, clamshell 

containers, draw string plastic bags, hermetically-sealed canister bags, or nothing 

at all. 

If over cases, packaging, or shipping containers are provided by the applicant 

over and above the minimum packaging configuration, these additional 

packaging levels may not be a substitute for the minimum packaging 

configuration and will not be used by NIOSH in the durability conditioning of the 

application. 

* End user: The definition of the end user is the person who will derive protection 

from the respirator by wearing it. It is assumed that the end user will store the 

respirator in a location where it will be available for immediate access and use 

during an emergency. 

1.2 Durability conditioning will be performed in accordance with Table 1 

Table 1 — Durability conditioning 

Test Test Method Test Condition Duration 

Hot Diurnal Mil-Std-810F; Method 

501.4; Table 501.4-II; 

Hot-Induced 

Conditions 

Diurnal Cycle, 35° C (95° F) 

to 71° C (160° F) 

3 Weeks 

Cold Constant Mil-Std-801F, Method 

502.4 

Basic Cold (C1), -32° C 

-25.6° F); Constant 

72 Hours 

Humidity Mil-Std-810E, 507.3; 

Method 507.3; Table 

507.3-II 

Natural Cycle, Cycle 1, 

Diurnal Cycle, 31° C (88°F) 

RH 88% to 41° C (105° F) RH 

59% 

5 Days, Quick Look 

Vibration Mil-Std-810F, 514.5 U.S. Highway Vibration, 

Unrestrained 

Figure 514.5C-1 

12 Hours/Axis, 3 Axis; 

Total Duration = 36 

Hours, equivalent to 

12,000 miles 

Drop 3 foot drop onto bare 

concrete surface 

Canister only; In individual 

canister packaging containter 

1 drop/filter on one of 

the 3 axes 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-19 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.3 Extra batteries (not subjected to the durability conditioning) are required 

for certification testing 

2.0 Chemical Agent Permeation and Penetration Resistance against Distilled Sulfur 

Mustard (HD) and Sarin (GB) Agent Requirement - (Reference STPs CBRN - 0550 and 

0551) 

2.1 The PAPR, while the blower is running and including all components and 

accessories except for the battery (or batteries), will resist the permeation and 

penetration of distilled sulfur mustard (HD) and Sarin (GB) chemical agents when 

tested on an upper-torso manikin connected to a breathing machine operating at 

an airflow rate of 40 L/min, 36 respirations per minute, and 1.1 liters tidal 

volume. Test requirements for distilled sulfur mustard (HD) are shown in Table 

2. Test requirements for Sarin (GB) agent are shown in Table 3. For tight-fitting 

PAPRS, two systems will be used for preliminary screening. Chemical agent 

permeation and penetration resistance testing will be performed on four tightfitting PAPRS (two for HD and two for GB) following the durability conditioning of 

Paragraph 1.0. 

Table 2 —Vapor-liquid sequential challenge with distilled sulfur mustard (HD) 

Agent Challenge 

Concentration 

Duration 

Of 

Challenge 

(min) 

Breathing 

Machine 

Airflow 

Rate 

(L/min) 

Maximum 

Peak 

Excursion 

(mg/m3

) 

Maximum 

Breakthrough 

(concentration 

integrated over 

minimum test 

time) 

(mg-min/m3) 

Number 

Of 

Systems 

Tested 

Minimum 

Test Time 

(hours) 

HDVapor 50 mg/m3* 30* 40 0.30‡ 3.0§ 3 8†† 

HDLiquid 0.43 to 

0.86 

ml

*,†,** 

120* 40 0.30‡ 3.0‡ 3 2 

* Vapor challenge concentration will start immediately after the test chamber has been 

sealed. Minimum test time for liquid exposure starts after the first liquid drop is 

applied. † Liquid Volume is dependent on accessories used with the respirator. Minimum volume 

is 0.43 ml based on the respirator only. Liquid challenge required on CBRN tight-fitting 

PAPRs only. ‡ Three consecutive sequential test data points at or exceeding 0.3 mg/m3 will collectively 

constitute a failure where each test value is based on a detector sample time of 

approximately two (2) minutes. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-20 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

§ The cumulative Ct including all maximum peak excursion data points must not be 

exceeded for the duration of the test. ** Liquid agent is applied to respirator at hour six (6) of the vapor test cycle. 

†† The test period begins upon the initial generation of vapor concentration and ends 

at eight (8) hours. Supplemental electrical power to the PAPR is permissible to allow 

the system to run for the purpose of this test. 

Table 3—Vapor challenge with Sarin (GB) 

Agent Challenge 

Concentration 

Duration 

of 

Challenge 

(min) 

Breathing 

Machine 

Airflow 

Rate 

(L/min) 

Maximum 

Peak 

Excursion 

(mg/m3) 

Maximum 

Breakthrough 

(concentration 

integrated over 

minimum test 

time) 

(mg-min/m3) 

Number 

of 

Systems 

Tested 

Minimum 

Test Time 

(hours) 

GB 210* 30* 40 0.044‡ 1.05§ 3 8†† 

*

The vapor challenge concentration generation will be initiated immediately after 

test chamber has been sealed. † The test period begins upon initial generation of vapor concentration and ends at 

eight (8) hours. Supplemental electrical power to the PAPR is permissible to allow the 

system to 

run for the purpose of this test. ‡ Three consecutive sequential test data points at or exceeding 0.044 mg/m3 will 

collectively constitute a failure where each test value is based on a detector sample 

time of approximately two (2) minutes. § The cumulative Ct including all maximum peak excursion data points must not be 

exceeded for the duration of the test. 

3.0 Laboratory Respiratory Protection Level (LRPL) Test Requirement – (all 

Respirators, Reference STP CBRN 0552) 

3.1 The measured laboratory respiratory protection level (LRPL) for each powered, 

air-purifying respirator will be 10,000 for > 95% trials with the blower operating 

(Blower On mode). The respirator is tested in an atmosphere containing 20–40 

mg/m3 corn oil aerosol of a mass median aerodynamic diameter of 0.4–0.6 μm. 

3.2 The measured laboratory respiratory protection level (LRPL) for each tight-fitting 

powered air-purifying respirator will be 2,000 for > 95% trials with the blower not 

operating (Blower Off mode). A modified LRPL using a sample size of eight 

subjects will be used for evaluation. The respirator is tested in an atmosphere 

containing 20–40 mg/m3 corn oil aerosol of a mass median aerodynamic 

diameter of 0.4–0.6 μm. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-21 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.3 This test will be performed with the PAPR fully accessorized with any 

components identified in the assembly matrix and submitted for 

certification. 

4.0 Canister and Cartridge Test Challenge and Test Breakthrough Concentrations– 

Reference STPs CBRN – 0501, 0502, 0503, 0504, 0505, 0506, 0507, 0508, 0509, 0510 

4.1 Canisters (tight-fitting PAPR) 

4.1.1 The gas/vapor test challenges and breakthrough concentrations are shown in 

Table 4. Canister capacity tests will be performed at room temperature, 

25 oC ± 2.5 °C; and at 25% ± 2.5% relative humidity and 80% ± 2.5% relative 

humidity. Three canisters will be tested at each specified humidity. Canister 

test time will be identified in 15-minute intervals (15 minutes, 30 minutes, 45 

minutes). For a service life of 60 minutes or greater, applications will be 

identified in 30-minute intervals (60 minutes, 90 minutes, 120 minutes). 

Canister capacity testing for the system will be tested at a flow rate of 115 Lpm 

divided by the least number of canisters used on any configuration of the 

system for which approval is sought. Canister capacity testing will be performed 

following the durability conditioning. 

Table 4 —Canister test challenge and test breakthrough concentrations 

Test 

Concentration 

(ppm) 

Breakthrough Concentration (ppm) 

Ammonia 2,500 12.5 

Cyanogen Cchloride 300 2 

Cyclohexane 2,600 10 

Formaldehyde 500 1 

Hydrogen Cyanide 940 4.7* 

Hydrogen Sulfide 1,000 5.0 

Nitrogen Dioxide 200 1 ppm NO2 or 25 ppm NO† 

Phosgene 250 1.25 

Phosphine 300 0.3 

Sulfur Dioxide 1,500 5 

* Sum of HCN and C2N2. 

† Nitrogen Dioxide breakthrough is monitored for both NO2 and NO. The breakthrough is 

determined by which quantity, NO2 or NO, reaches breakthrough first. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-22 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2 Cartridges (loose-fitting PAPR) 

4.2.1 The gas/vapor test challenges and breakthrough concentrations are shown 

in Table 5. Cartridge capacity tests will be performed at room temperature, 

25 oC ± 2.5 °C; and at 25% ± 2.5% relative humidity and 80% ± 2.5% relative 

humidity. Three cartridges will be tested at each specified humidity. 

Cartridge test time will be identified in 15-minute intervals (15 minutes, 30 

minutes, 45 minutes). For a service life of 60 minutes or greater, 

applications will be identified in 30-minute intervals (60 minutes, 

90 minutes, 120 minutes). Cartridge capacity testing for the system will be 

tested at a flow rate of 170 Lpm divided by the least number of canisters 

used on the system for which approval is sought. 

Table 5 —Cartridge test challenge and test breakthrough concentrations 

Test 

Concentration 

(ppm) 

Breakthrough Concentration (ppm) 

Ammonia 1,250 12.5 

Cyanogen Chloride 150 2 

Cyclohexane 1,300 10 

Formaldehyde 250 1 

Hydrogen Cyanide 470 4.7* 

Hydrogen Sulfide 500 5.0 

Nitrogen Dioxide 100 1 ppm NO2 or 25 ppm NO† 

Phosgene 125 1.25 

Phosphine 150 0.3 

Sulfur Dioxide 750 5 

* Sum of HCN and C2N2. 

† Nitrogen Dioxide breakthrough is monitored for both NO2 and NO. The breakthrough is 

determined by which quantity, NO2 or NO, reaches breakthrough first. 

4.3 Particulate/aerosol testing 

4.3.1 The canister/cartridge will meet the requirements of 99.97% particulate filter efficiency in 

accordance with the following criteria. Particulate filter efficiency testing will be performed 

following the durability conditioning. 

4.3.2 Twenty (20) canisters/cartridges will be tested for filter efficiency against a dioctyl 

phthalate or equivalent liquid particulate aerosol. 

4.3.2.1 Additionally, six canisters/cartridges from the cyclohexane 

gas life test of paragraphs 4.1 and 4.2 will be tested for filter 

efficiency against dioctyl phthalate or equivalent liquid particulate 

aerosol. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-23 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.3.3 The canister/cartridge including holders and gaskets, when separable, will 

be tested for filter efficiency level, as mounted on a test fixture in the 

manner as used on the respirator. 

4.3.4 When the canister/cartridge does not have separable holders and 

gaskets, the exhalation valves will be blocked to ensure that leakage, if 

present, is not included in the filter efficiency level evaluation. 

4.3.5 Cartridge particulate testing for loose-fitting PAPR systems will be tested 

at a flow rate of 170 Lpm divided by the least number of cartridges used 

on the system for which approval is sought. Canister particulate testing 

for the tight-fitting system will be tested at a flow rate of 115 Lpm 

divided by the least number of canisters used on the system for which 

approval is sought. 

4.3.6 A neat cold-nebulized dioctyl phthalate (DOP) or equivalent aerosol at 

25oC ± 5°C that has been neutralized to the Boltzmann equilibrium 

state will be used. Each canister/cartridge will be challenged with a 

concentration not exceeding 200 mg/m3. 

4.3.7 The test will continue until minimum efficiency is achieved or until an 

aerosol mass of at least 200 mg ± 5 mg challenge point is reached. The 

test will be continued until there is no further decrease in efficiency 

4.3.8 The DOP aerosol will have a particle size distribution with count median 

diameter of 0.185 μm ± 0.020 μm and a standard geometric deviation 

not exceeding 1.60 at the specified test conditions as determined with a 

scanning mobility particle sizer or equivalent. 

4.3.9 The efficiency of the canister/cartridge will be monitored throughout the 

test period by a suitable forward-light-scattering photometer or 

equivalent instrumentation and recorded. 

4.3.10 Current test technology limits flow rate testing to 95 Lpm. When test 

equipment has been validated to test at higher flows, single filter 

elements will be able to be evaluated. 

5.0 CBRN PAPR Upgrade Retrofit 

Once the system(s) has(have) met the requirements for 42 CFR Part 84 and subsequent CBRN 

PAPRapproval, manufacturers may apply for approval of CBRN PAPR retrofit kits to upgrade 

existing42 CFR Part 84 PAPR to CBRN PAPR standards. In doing so, the following applies: 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-24 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.1 PAPR units must be 42 CFR Part 84 and CBRN PAPR approved prior to 

submitting an application for upgrading to CBRN capability 

5.2 Retrofit of previously approved 42 CFR Part 84 and CBRN tight-fitting PAPR 

must be performed in accordance with manufacturer instructions, to ensure 

the retrofit complies with the approved CBRN PAPR configuration, quality 

assurance, and performance requirements 

5.3 The CBRN PAPR retrofit kit must, as a minimum, contain the following: 

- CBRN PAPR retrofit kit instructions 

- Replacement packaging, components, parts, materials, CBRN canisters or 

cartridges (as applicable), and operation instructions required to retrofit the 

PAPR to the identical configuration as the approved CBRN configuration level 

(including minimum packaging configuration) 

- CBRN PAPR retrofit approval label(s) for the respirator retrofit kit 

- Respirators which are to be retrofitted must be in “fully operational and 

protective condition” 

5.4 Manufacturers will need to submit a Standard Application Form and 

associated documents which clearly define the respirators eligibility for 

retrofit and explain the configuration changes achieved with the retrofit kit 

5.5 The manufacturer must provide four PAPRs which have been in service for 

one to five years. As a minimum, submitted respirators are to be from two 

different conditions of use: Two from a light condition of use category. Light 

use is defined as a PAPR primarily in a storage configuration; used 

intermittently throughout the service life. Two from a heavy condition of 

use category. Heavy use is defined as PAPR used routinely for respiratory 

protection as part of an OSHA-compliant respirator program. 

5.6 The units should be supplied with the retrofit kit installed 

5.7 NIOSH testing performed on the respirators will be evaluated to the special 

tests for chemical agent permeation and penetration resistance against 

Distilled Mustard (HD) and Sarin (GB) for each respirator use condition 

provided plus any other tests described above or as deemed necessary by 

NIOSH 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-25 
 

 

 

Air-Purifying Escape Respirators (APER) 

with CBRN Protection 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-26 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

September 30, 2003 

Attachment A 

Statement of Standard 

For 

Chemical, Biological, Radiological, and Nuclear (CBRN) 

Air-Purifying Escape Respirator 

1.0 Purpose: 

The purpose of this standard is to specify minimum requirements to determine the 

effectiveness of air-purifying escape respirators that address CBRN materials identified 

as inhalation hazards from possible terrorist events for use by the general working 

population. The air-purifying escape respirator must meet the minimum requirements 

identified in the following Paragraphs: 

x Paragraph 2.0, Requirements Specified in Title 42, Code of Federal 

Regulations (CFR), Part 84 applicable paragraphs, 

x Paragraph 3.0, Requirements based on existing national and 

international standards, 

x Paragraph 4.0, Special requirements for CBRN use. 

2.0 Title 42 Code of Federal Regulations (CFR), Part 84: 

The following paragraphs of 42 CFR, Part 84 are applicable: 

2.1 42 CFR, Part 84, Subparts A, B, D, E, F, and G: 

Subpart A: General Provisions Subpart 

B: Application for Approval Subpart D: 

Approval and Disapproval Subpart E: 

Quality Control 

Subpart F: Classification of Approved Respirators 

Subpart G: General Construction and Performance 

3.0 Requirements Based on Existing National and International Standards: 

3.1 Breathing Resistance: 

The resistance of airflow will be measured at the breathing zone (nose cup or 

mouthpiece) of an air-purifying escape respirator mounted on a head form test 

apparatus operated at a continuous airflow rate of 85 Liters per minute (Lpm). The 

inhalation resistance will not exceed 70 mm H2O and the exhalation resistance will not 

exceed 20 mm H2O. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-27 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.2 Field of View: 

The air-purifying escape respirator will obtain a Visual Field Score (VFS) of 70 or 

greater when tested in accordance with NIOSH Standard Test Procedure CET-APRSSTP-CBRN-0314. The VFS will be obtained by using a medium size respirator or 

equivalent that is sized to fit the Head Form described in Figure 14 of EN 136, 

Respiratory protective devices – Full face masks – Requirements, testing, marking; 

January 1998 or equivalent. 

The VFS is determined by using a VFS grid (Dots on visual field) as defined in the 

American Medical Association Guides to the Evaluation of Permanent Impairment, 

5th Edition (2000) that is overlaid on the diagram of the visual field plot obtained using 

the spherical shell of EN 136 apertometer or equivalent. The VFS score is the average of 

three fittings of the same respirator on the specified head form. 

3.3 Fogging: 

The air-purifying escape respirator will demonstrate an average Visual Acuity Score 

(VAS) of greater or equal to 70 points for all measurements for each individual. A 

minimum of two respirators shall be evaluated. 

The respirator will be donned by the test subject in an indoor ambient temperature 

of approximately 72+20 F at 40+5% Relative Humidity (RH) and then will enter into a 

simulated outdoor extreme temperature chamber where the visual acuity tests will 

be administered. The air-purifying escape respirator will be tested for fogging in the 

hot/humid condition of 90+20F and 60+5% RH, and the cold condition of 13+20F. 

3.4 Breathing Gas: 

Breathing gas criteria will be evaluated as a two-part requirement: 1) a dead-space 

carbon dioxide test performed with a breathing machine and 2) carbon dioxide and 

oxygen concentrations during human test subject exercises. The wearer will not 

experience undue discomfort because of restrictions to breathing or other physical or 

chemical changes to the respirator. All trials will be considered as part of the Practical 

Performance criteria of paragraph 4.8. 

3.4.1 Breathing Machine 

The maximum allowable average inhaled carbon dioxide concentration will be less than 

or equal to one percent, measured at the mouth, while the air-purifying escape respirator 

is mounted on a dummy head operated by a breathing machine. The breathing rate will 

be 14.5 respirations per minute with a minute volume of 10.5 Liters. Tests will be 

conducted at ambient temperature of 25 ± 5°C. A concentration of five percent carbon 

dioxide in air will be exhaled into the facepiece. The minimum allowable oxygen 

concentration will be that of the ambient room oxygen concentration. NIOSH Test 

Procedure RCT-APR-STP-0064 is used for carbon dioxide testing. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-28 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.4.2 Human Subject Testing 

During the testing required by this section, the concentration of inspired carbon 

dioxide gas at the mouth will be continuously recorded, and the calculated maximum 

range concentration during the inhalation portion of the breathing cycle will not 

exceed the limits as stated in Table 1. 

Table 1.—Inspired carbon dioxide limits 

Where the service time is Maximum time-weighted fractional concentration of 

inspired carbon dioxide 

15 min or 30 min 0.025 (or 2.5%) 

45 min or 60 min 0.020 (or 2.0%) 

The inhaled carbon dioxide concentration will be as indicated in the above table. The 

inhaled fractional oxygen concentration will be no less than 0.195 (or19.5%) when 

tested with human subjects at the following work rates: standing and walking at 3.5 miles 

per hour. Two tests (standing and walking at 3.5 miles per hour) will be performed, 

each using 12 test subjects. Table 2 gives face length and width criteria, which the 

subjects will be required to fill. Table 2 is applicable for ‘one size fits all air-purifying 

escape respirator’ or an air-purifying escape respirator with small, medium, and large 

sizes. For other variations in air-purifying escape respirator size, test subjects will be 

determined to provide for panel range of Table 2. 

Table 2.—Test design criteria 

*LANL Boxes – ‘Small’ *LANL Boxes – ‘Medium’ *LANL Boxes – ‘Large 

1, 2, 3, 4 3, 4, 5, 6, 7, 8 7, 8, 9, 10 

Four subjects in ‘Small’ 

boxes. More than one 

subject possible in any 

box. 

Four subjects in ‘Medium’ 

boxes. More than one subject 

possible in any box. 

Four subjects in ‘Large’ boxes. 

More than one subject 

possible in any box 

*Adapted from the Los Alamos National Laboratory report respirator test panel 

Each exercise will be performed for 10 minutes. Carbon dioxide and oxygen data will be 

considered for the last five minutes of each exercise. For each of these last five minutes, 

the last five breaths will be considered. 

For each group of 12 subjects, 95% of the total number of trials must meet the stated 

criteria. Should a group of test trials not pass the 95% of trials, one addition run of 

test trials consisting of 12 test subjects may be performed to increase the total 

number of trials; the total number of trials (total of 48) will be the sum of trials from 

the first and second run of subjects. All trials will be considered in the Practical 

Performance requirement criteria of paragraph 4.8. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-29 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.5 Flammability and Heat Resistance (applicable ONLY to respirators approved 

for carbon monoxide protection): 

Air-purifying escape respirators submitted for approval for carbon monoxide protection will 

be tested for Flammability and Heat Resistance using the test equipment specified in EN 136, 

Respiratory Protective Devices, Full Face Masks, Requirements, Testing, Marking, 1998 

Edition, Class 1 facepiece. No component of the respirator will have an after flame after 

five seconds. No component of the escape respirator will drip, melt, or develop a visible 

hole. 

The distance between the outer surface of the escape respirator and the burner will 

be adjusted to 20 ± 2 mm. The pressure reducer will be adjusted to 2.1 ± .05 psi. The 

temperature of the flame positioned above the burner tip shall be 800 ± 500 C at a point 20+2 mm 

above the tip. The respirator will be rotated once through the flame at a velocity of 6 ± 0.5 cm/s. 

Where components of the respirator such as valves, filters, etc. are arranged on the respirator, 

the test will be repeated with these components at the appropriate height of 250 mm ± 6.4 mm. 

3.6 Design Considerations: 

3.6.1 Function: 

The air-purifying escape respirator will provide a barrier from ambient conditions for the 

wearer’s entire head, eyes, and respiratory system. The air-purifying escape respirator 

will not require the use of hands to maintain the respirator position to ensure proper 

function of the respirator when fully donned. 

3.6.2 Hood Type Device: 

The air-purifying escape respirator will be designed as a hooded device. The hood will 

include an area for field of vision. A hood is a respirator component which covers the 

wearer’s head and neck, or head, neck, and shoulders, and is supplied with incoming 

respirable air for the wearer to breathe. 

3.6.3 Respiratory Protection System: 

The respiratory protection system may consist of an oral/nasal cup or mouthpiece. If a 

mouthpiece is employed, a method of preventing nasal breathing must be provided. An 

oral/nasal cup or a mouthpiece is not required provided all requirements of this 

standard are fulfilled by the air-purifying escape respirator. 

4.0 Special CBRN Requirements: 

4.1 Duration Rating: 

Escape respirators will be rated for 15, 30, 45, or 60-minute duration as specified by the 

manufacturer. Only one duration rating can apply to any respirator. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-30 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2 Canister Test Challenge and Test Breakthrough Concentrations. 

4.2.1 General Category 

Escape respirators will meet the gas/vapor test challenge concentrations in Table 3, 

when tested in accordance with 4.3 Gas Life requirements. 

Table 3.—Gas/vapor test challenge concentrations 

Agent Test Challenge(ppm) Breakthrough (ppm) 

Ammonia 1250 25 

Cyanogen Chloride 150 2 

Cyclohexane 1300 10 

Formaldehyde 

Hydrogen Cyanide 

250 

470 

10 

10* 

Hydrogen Sulfide 500 30 

Nitrogen Dioxide 100 1 ppm NO2 

Phosgene 125 1.25 

Phosphine 150 0.5 

Sulfur Dioxide 750 5 

* Sum of HCN and C2N2. 

4.2.1.1 General Category Escape Respirator Multi Gas/Vapor/Particulate with 

Carbon Monoxide Requirements: 

Escape respirators intended for use at the General category with carbon 

monoxide protection will meet the requirements of paragraph 4.2.1 plus carbon 

monoxide. 

For the general category, the test challenge concentration will be 3600 ppm. The 

maximum allowable carbon monoxide penetration will not exceed the values 

identified in the Table 4. The penetration of carbon monoxide will not exceed a 

maximum peak excursion of 500 ppm at any point of the test. 

Table 4.—Carbon monoxide penetration limits 

Identified Service Life (Minutes) Concentration-time (Ct) (ppm-minutes) 

15 6037 

30 12075 

45 18111 

60 24150 

The respirators will be evaluated under the following test conditions: 

a) Three respirators tested at 64+10 Lpm continuous airflow at 89 to 95% relative 

humidity, 25+30C 

b) Three respirators tested at 64+10 Lpm continuous airflow at 89 to 95% relative 

humidity, 0+2.50

C 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-31 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2.1.1.1 Service Life Testing, High Flow, Carbon Monoxide: 

The escape respirator will provide a minimum duration of five minutes when tested at 

a flow rate of 100+10 Lpm, 89 to 95% relative humidity, 25+30C, when tested at a 

challenge concentration of 3600 ppm. The penetration of carbon monoxide will not 

exceed a maximum peak excursion of 500 ppm at any point of the test. The maximum 

allowable carbon monoxide penetration shall not exceed an overall Ct of 2013 ppmminutes. Three respirators will be tested. 

4.2.1.1.2 Inspired Air Temperature, Carbon Monoxide: 

Three escape respirators mounted to a head form and connected to a breathing 

machine, cycling at 40Lpm, 36 respirations per minutes, 1.1 Liters tidal volume, will be 

tested with a challenge concentration of 1200 ppm (IDLH), at 89 to 95% relative humidity 

and 

25+2.5oC. The inspired air temperature measured at the facepiece must always be less 

than or equal to 46 °

C (dry bulb) with less than or equal to 10 ppm CO for the entire test if 

the inspired air humidity is less than or equal to 50%. The inspired air temperature must 

be less than or equal to 41 °C (dry bulb) with less than or equal to 10 ppm CO for the 

entire test if the inspired air relative humidity is greater than 50%. NIOSH test procedure 

RCT-APR-STP-0034 will be used. 

4.2.2 Specific Category: 

Escape respirators intended for use at the specific hazard threat category conditions will 

meet the gas/vapor testing of paragraph 4.2.1. In addition to the test requirements of 

paragraph 4.2.1, test concentrations for additional specific test agent protections will be 

as specified in Table 5. 

Table 5.—Agent challenge concentrations 

Agent Test Challenge (ppm) 

Ammonia 2500 

Cyanogen Chloride 300 

Cyclohexane 2600 

Formaldehyde 500 

Hydrogen Cyanide 940 

Hydrogen Sulfide 1000 

Nitrogen Dioxide 200 

Phosgene 250 

Phosphine 300 

Sulfur Dioxide 1500 

Additional specific test agent protections can be added to the minimum as specified 

by the applicant for any combination of the listed test agents. Test breakthrough 

concentrations for the specific category will be the breakthrough concentrations 

identified in paragraph 4.2.1. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-32 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.2.2.1 Specific Category Escape Respirator Multi Gas with Carbon Monoxide 

Requirements: 

Escape respirators intended for use at the Specific category with carbon monoxide 

protection will meet the requirements of paragraph 4.2.2 for the requested test 

agent protection, plus carbon monoxide. 

For the specific category, the carbon monoxide test challenge concentration will be 6000 

ppm. The maximum allowable carbon monoxide penetration will not exceed the values 

identified in paragraph 4.2.1.1 and Table 4. 

4.2.2.1.1 Service Life Testing, High Flow, Carbon Monoxide: 

The escape respirator will provide a minimum duration of five minutes when tested at 

a flow rate of 100+10 Lpm, 89 to 95% relative humidity, 25+30C, when tested at a 

challenge concentration of 6000 ppm. The penetration of carbon monoxide will not 

exceed a maximum peak excursion of 500 ppm at any point of the test. The maximum 

allowable carbon monoxide penetration will not exceed a Ct of 2013 ppm-minutes. 

Three respirators will be tested. 

4.2.2.1.2 Inspired Air Temperature, Carbon Monoxide: 

Three systems mounted to a head form and connected to a breathing machine, cycling at 

40 Lpm, 36 respirations per minute, 1.1 Liters tidal volume, will be tested with a 

challenge concentration of 1200 ppm IDLH (IDLH) at 89 to 95% relative humidity and 

25+2.5oC. The inspired air temperature measured at the facepiece must always be 

less than or equal to 46 °C (dry bulb) and less than or equal to 10 ppm CO for the entire 

test 

if the inspired air humidity is less than or equal to 50%. The inspired air temperature 

must be less than or equal to 41 °C (dry bulb) and less than or equal to 10 ppm CO for 

the entire test if the inspired air relative humidity is greater than 50%. NIOSH test 

procedure RCT-APR-STP-0034 will be used. 

4.3 Gas Life: 

Gas life tests are performed at room temperature, 25±50C; 25±5 percent relative 

humidity, and 80±5 percent relative humidity. Three filters will be tested at each 

specified humidity with a flow rate of 64+10 Lpm, continuous flow. Tests will be 

conducted to minimum specified service time. Gas testing will be performed following 

environmental conditioning and rough handling. The breakthrough concentration must 

be no greater than the specified breakthrough for each tested gas in Table 3. Testing is 

terminated after the applicant’s specified service time is achieved. 

4.4 Particulate/Aerosol Canister: 

The canister will meet the requirements of a P100 particulate filter in accordance with 

the following criteria of 42 CFR, Part 84. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-33 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1) Twenty filters for the air-purifying respirator will be tested for filter efficiency against a 

dioctyl phthalate or equivalent liquid particulate aerosol. 

2) Filters including holders and gaskets; when separable will be tested for filter 

efficiency level, as mounted on a test fixture in the manner as used on the 

respirator. 

3) When the filters do not have separable holders and gaskets, the exhalation valves will 

be blocked so as to ensure that leakage, if present, is not included in the filter efficiency 

level evaluation. 

4) For air-purifying particulate respirators with a single filter, filters will be tested at a 

continuous airflow rate of 85 + 4 liters per minute. Where filters are to be used in pairs, 

the test-aerosol airflow rate will be 42.5 + 2 liters per minute through each filter. 

5) A neat cold-nebulized dioctyl phthalate (DOP) or equivalent aerosol at 25 + 5oC that 

has been neutralized to the Boltzmann equilibrium state will be used. Each filter will be 

challenged with a concentration not exceeding 200 mg/m3. 

6) The test will continue until minimum efficiency is achieved or until an aerosol mass of 

at least 200 + 5 mg has contacted the filter. If the filter efficiency is decreasing when 

the 200 + 5 mg challenge point is reached, the test will be continued until there is no 

further decrease in efficiency. 

7) The DOP aerosol will have a particle size distribution with count median diameter of 

0.185 + 0.020 micrometer and a standard geometric deviation not exceeding 1.60 at 

the specified test conditions as determined with a scanning mobility particle sizer or 

equivalent. 

8) The efficiency of the filter will be monitored and recorded throughout the test period 

by a suitable forward-light-scattering photometer or equivalent instrumentation. 

9) The minimum efficiency for each of the 20 filters will be determined and recorded 

and be equal to or greater than the filter efficiency criterion listed for the P100 filter: 

>99.97%. 

4.5 Service Life Testing, High Flow: 

Each escape respirator will provide a minimum duration of five minutes when tested 

at a flow rate of 100+10 Lpm, 50+5 percent relative humidity and 25+50C for each of 

the gases/vapors identified in paragraphs 4.2.1 and 4.2.2. 

4.6 Chemical Agent Permeation and Penetration Resistance Against Distilled Sulfur 

Mustard (HD) and Sarin (GB) Agent Requirement: 

The air-purifying escape respirator system, including all components and accessories 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-34 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

will resist the permeation and penetration of Distilled Sulfur Mustard (HD) and Sarin 

(GB) chemical agents when tested on an upper-torso manikin connected to a 

breathing 

Test requirements for Sarin (GB) agent are shown in Table 7. 

machine operating at an airflow rate of 40 Lpm, 36 respirations per minute, 1.1 Liters 

tidal volume. 

Test requirements for Distilled Sulfur Mustard (HD) are shown in Table 6. 

Table 6.—Vapor-Liquid Sequential Challenge of Air-Purifying Escape Respirator 

with Distilled Sulfur Mustard (HD) 

Agent Challenge Duration of Breathing Maximum Maximum Number Minimum 

Concentration Challenge 

(min) 

Machine 

Airflow 

Rate 

Peak 

Excursion 

(mg/m3) 

Breakthrough 

(concentration 

integrated 

of 

Systems 

Tested 

Test Time 

(hours) 

(Lpm) over minimum 

service life) 

(mg-min/m3) 

3* *,** 

50 mg/m 15/30/45/6 HD Vapor 0 † *,** ‡ §,‡‡ †† 

HD Liquid 0.43 to 0.86 ml 15/30/45/6 40 0.60 6.0 3 30/60/90/120 

0 

* Vapor challenge concentration will start immediately after the liquid drops have been applied and the test 

chamber has been sealed. 

†. Minimum volume is 0.43 ml based on the respirator and single canister. Liquid volume is applied as 25 drops of 

equal size. 

‡ Three consecutive sequential test data points at or exceeding 0.6 mg/m3 will collectively constitute a failure 

where each test value is based on a detector sample time of approximately two minutes. 

§ The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of 

the test. 

** Duration of challenge is 15, 30, 45, or 60 minutes, equal to applicant’s identified rated duration (para 4.1) 

†† Minimum Test Life is 30, 60, 90, or 120 minutes, equal to twice the applicant’s rated duration (para 4.1) 

‡‡ Respirators will be monitored in the oral/nasal and ocular regions 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-35 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 7.—Vapor Challenge of Air-Purifying Escape Respirator with Sarin (GB) 

Challenge Vapor Vapor Breathing Maximum Maximum Number Minimum 

Concentration Concentration Challenge Machine Peak Breakthrough of Test Time 

(mg/m3) Time Airflow Excursion (concentration Systems (hours) 

(minutes) Rate mg/m3 integrated Tested 

(Lpm) over minimum 

service life) 

(mg-min/m3) 

0.9 for 15 and 

30 minute 

devices 

GB 210 15/30/

45/60 

40 0.08‡ 

2.1 for 45 and 

3 30/60/90/120 

60 minute 

devices§,‡‡ 

* The vapor challenge concentration generation will be initiated immediately after test chamber has been sealed. 

† The test period begins upon initial generation of vapor concentration. 

‡ Three consecutive sequential test data points at or exceeding 0.087 mg/m3 will collectively constitute a 

failure where each test value is based on a detector sample time of approximately two minutes. 

§ The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of 

the test. The breakthrough duration is based upon the applicant’s identified duration. 

** Duration of challenge is 15, 30, 45, or 60 minutes, equal to applicant’s identified rated duration (para 4.1). 

†† Minimum Test Life is 30, 60, 90, or 120 minutes, equal to twice the applicant’s identified rated duration (para 

4.1). 

‡‡ Respirators will be monitored in the oral/nasal and ocular regions 

4.7 Laboratory Respiratory Protection Level (LRPL) Test Requirement: 

The measured laboratory respiratory protection level (LRPL) for each air-purifying escape 

respirator will be 2000 or greater, for 95% of trials, sampled in the breathing zone of the 

respirator, and will be 150, or greater, for 95% of trials, sampled outside the breathing zone 

(under the hood). Each trial must meet the breathing zone criteria and 

‘under the hood’ criteria simultaneously for the trial to be considered passing. Test subject 

and replication numbers are outlined in Table 8. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-36 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 8.—Anthropometric test criteria 

Small Medium Large 

Face Length 

and 

Face Width 

Cell A 

*Use LANL boxes 1, 2, 

3, 4 (2 or 3 subjects each 

box, 2 trials per subject) 

Subjects= 10 

Trials= 20 

Cell D 

*Use LANL boxes 3, 4, 5, 6, 7, 

8; panel size 17 (2 or 3 

subjects each box, 2 trials per 

subject) 

Subjects= 17 

Trials= 34 

Cell G 

*Use LANL boxes 7, 8, 9, 10; 

panel size 11 (2 or 3 subjects 

each box, 2 trials per subject) 

Subjects= 11 

Trials= 22 

Head 

Circumference 

Cell B 

N/A 

Subjects= 0 

Trials= 0 

Cell E 

N/A 

Subjects= 0 

Trials= 0 

Cell H 

570-603 mm 

Subjects= 10 

Trials= 20 

Neck 

Circumference 

Cell C 

306-378 mm 

Subjects= 10 

Trials= 20 

Cell F 

355-403 mm 

Subjects= 10 

Trials= 20 

Cell I 

378-451 mm 

Subjects= 10 

Trials= 20 

*Adapted from the Los Alamos National Laboratory report respirator test panel 

The respirator is tested in an atmosphere containing 20-40 mg/m3 corn oil aerosol of a 

mass median aerodynamic diameter of 0.4 to 0.6 micrometers. Should a group of test 

subjects result in LRPL trials where less than 95% of trials have passing results, one 

additional run of test subjects that fills the entire anthropometric panel requirements 

may be performed to increase the total number of trials; the total number of trials will 

be the 

sum of trials from the first and second run of subjects. All trials will be considered in the 

Practical Performance criteria of paragraph 4.8. The LRPL will be calculated using nine 

exercises: Normal Breathing, Deep Breathing, Turn Head Side to Side, Move Head Up and 

Down, Reach for the Floor and Ceiling, On Hands and Knees - Look Side to Side, Facial 

Grimace, Climb Stairs at a Regular Pace, and Normal Breathing. 

For each size category (Small, Medium, and Large), each cell corresponding to the 

anthropometric parameter will be tested. Cells can be either consecutively tested (if the 

test subjects only meet the requirements of a specific cell) or simultaneously tested (if 

the test subjects meet the requirements of more than one cell) for each size category. 

4.8 Practical Performance: 

The Practical Performance of the air-purifying escape respirator will be evaluated as part 

of the test procedures of paragraphs 3.4, Breathing Gas, and 4.7, Laboratory Respirator 

Protection Level. The Practical Performance of the respirator will evaluate human 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-37 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

interface issues associated with the use of the escape respirator. As a minimum, 

contributing factors (if applicable based upon the respirator design) are: the use of 

mouth bits and nose clips; seal of the hood around the respirator wearer’s neck; seating 

of inner masks; position of the hood on the respirator wearer’s head; and strength 

required to don the respirator. Test subjects will be trained on proper use of the escape 

respirator in accordance with the applicant’s instructions identified in paragraph 8.0, 

Training. Inability of any test subject participating in the test procedures of paragraphs 

3.4, Breathing Gas, and 4.8, Laboratory Respirator Protection Level, to complete the test 

procedures will constitute a failure of the Practical Performance requirement for that 

trial. 

Practical Performance trials will be accumulated from the test procedures of paragraphs 

3.4, Breathing Gas, and 4.7, Laboratory Respirator Protection Level. For the total of these 

accumulated trials, 95% of these trials will exhibit acceptable Practical Performance. 

Should 95% of the Practical Performance test trials not be acceptable, one additional run 

of test trials consisting of either, or both, paragraph 3.4, Breathing Gas, or paragraph 4.8, 

Laboratory Respirator Protection Level, may be performed to increase the total number 

of trials. The total number of trials will be the sum of trials from the first and second run 

of subjects. 

4.9 Donning: 

The time to don the respirator from the ready-to-use configuration will be no greater 

than 30 seconds. The ready to use configuration is the operational packaging state 

prior to use such that immediately upon opening allows the user to don the respirator. 

4.10 Environmental Conditioning Requirements: 

Environmental, vibration, and drop conditioning will be performed on escape respirators 

in the ready-to-use configuration. The ready-to-use configuration is the operational 

packaging state prior to use, such that immediately upon opening allows the user to don 

the respirator. Respirators will be visually inspected following environmental 

conditioning to ensure no damage or deterioration has occurred that could negatively 

affect the intended use of the respirator. 

Environmental conditioning will be performed in accordance with Table 9. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-38 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 9.—Environmental Conditioning 

Test Test Method Test Condition Duration 

Hot Constant Mil-Std-810F, 

Method 501.4 0 71 C (160 F), Constant 5 Weeks 

Cold Constant 

Mil-Std-810F, 

Method 502.4 

0 0 Basic Cold, -32 C (-24 F); 

Constant 3 Days 

Humidity Mil-Std-810E, 507.3; 

Realistic, Natural Cycle 

Humidity Profiles in the 

U.S. 

5 Days, “Quick Look” 

Mil-Std-810E Table 

507.3-II 

Transportation/Vibration Mil-Std-810F, 514.5 

US Roadway Vibration, 

Unrestrained 

12 Hours/Axis, 3 Axis; 

Total Duration =36 

Hours, equivalent to 

12,000 miles 

Drop Standard Drop Test Height of 3 feet 1 drop on each of the 3 

Axes per Unit. 

4.11 Test Sequence and Quantity: 

Testing of the Escape Respirator shall follow Table 10. 

Table 10.—Test Sequence and Quantity 

Test 

Order 

Resistance 

and 

Breathing 

Gas 

Human 

Factors 

Service 

Life, 

100 Lpm 

Service 

Life Testing, 

64 Lpm 

flow 

Penetration 

and 

Permeation 

Testing 

Efficiency 

Particulate 

LRPL 

Test

† 

Qty 24* 3-9 30 60 6 * 20 30-65 

1 

Inhalation 

Resistance 

Para 3.1 

Donning 

Para 4.9 

Hot Constant 

Para 4.10 

Hot Constant 

Para 4.10 

Hot Constant 

Para 4.10 

Hot Constant 

Para 4.10 

LRPL 

Para 4.7 

2. 

Exhalation 

Resistance 

Para 3.1 

Fogging 

Para 3.3 

Cold 

Constant Para 

4.10 

Cold 

Constant Para 

4.10 

Cold 

Constant Para 

4.10 

Cold 

Constant Para 

4.10 

Practical 

Performance 

CO2 Machine 

3. Testing 

84.63 

(a)(b)(c)(d) 

Field of 

View 

Para 3.2 

Humidity Para 

4.10 

Humidity Para 

4.10 

Humidity Para 

4.10 

Humidity Para 

4.10 

Para.3.4.1 

4. 

Breathing 

Gas (Human 

Subjects) 

Para 3.4.2 

Flammability 

and Heat 

Resistance 

Para 3.5 

Transportation/ 

Vibration Para 

4.10 

Transportation/ 

Vibration Para 

4.10 

Transportation/ 

Vibration Para 

4.10 

Transportation/ 

Vibration Para 

4.10 

5. 

Practical 

Performance 

Para 4.8 

Drop 

Para 4.10 

Drop 

Para 4.10 

Drop 

Para 4.10 

Drop 

Para 4.10 

Service Life Service Life System Filter 

6. 100 Lpm 64 Lpm Testing Efficiency 

Para 4.3 Para 4.2 Para 4.6 Para 4.4 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-39 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

* A total six systems tests are performed, 3 GB and 3 HD. Two systems tests, 1 GB and 1 HD, are performed prior 

to Para. 4.10 Environmental Conditioning. Four systems tests, 2 GB and 2 HD, are performed after Para. 4.10 

Environmental Conditioning. 

† All tests in the Resistance and Breathing Gas and LRPL column are performed prior to Paragraph 4.10, 

Environmental Conditioning. 

5.0 Quality Assurance Requirements: 

5.1 Quality Control Plan: 

Respirators submitted for CBRN approval will be accompanied by a complete quality control 

plan meeting the requirements of Subpart E of 42 CFR, Part 84. 

5.2 Sampling/Test/Inspection Plan: 

The applicant will specify a sampling/test/inspection plan for respirator parts and materials to 

ensure the construction and performance requirements of this standard are established 

through the manufacturing process. As a minimum, specific attributes to be addressed are: 

a) Materials of construction used for respirator parts that form a barrier between the 

user and ambient air. 

b) Integrity of mechanical seals that comprise a barrier between the user and 

ambient air. 

c) Final performance quality control tests on complete air-purifying escape 

respirators demonstrating compliance with the gas life and particulate filter 

requirements of this standard. 

6.0 General Requirements: 

In addition to the requirements of 42 CFR, Subpart G – General Construction and 

Performance Requirements, the following requirements apply: 

Prior to making or filing any application for approval or modification of approval, the applicant 

will conduct, or cause to be conducted, examinations, inspections, and tests of respirator 

performance, which are equal to or exceed the severity of those prescribed in the standard. 

Chemical Agent Penetration and Permeation Resistance against Distilled Sulfur Mustard (HD) 

and Sarin (GB) tests, Paragraph 4.6, are excluded from this requirement. 

7.0 Useful Life and Maintenance: 

The applicant will identify an initial useful life, not to exceed five (5) years, of the escape 

respirator. The “useful life” is defined as the length of time a unit can remain deployed in the 

‘ready to use’ stowed condition. All applications for certification must specify useful service life 

with supporting data and rationale. Further, a rationale must be included for any sampling plan 

set forth in the user instructions which would extend the useful life of the escape respirator 

beyond any initial useful life. However, extensions of useful life will be determined during the 

last year of the initial useful life. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-40 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The following guidelines should be included in the useful service life plans: 

a. Useful life plans should be based upon reliability engineering methodology and 

describe the conditions for use for the unit. Each plan will be individually 

evaluated. 

b. All respirator service actions are the responsibility of the applicant, or their 

authorized representative. The user/owner of the respirators should perform basic 

inspections as described in the instruction manual and/or as required by federal 

regulations. 

c. In order for an escape respirator to receive an incremental useful life extension, 

some service action must be performed on each unit. 

d. After the service action has been performed, the applicant, or their authorized 

representative, should collect a random sample of the serviced units and performance 

test these respirators to verify that they function as approved. The purpose of postservice sampling and performance testing is to identify unexpected problems caused 

by uncontrolled or unpredicted factors. 

e. The applicant may define “performance testing” by specifying the following: 

test procedures, pass/fail standards, performance tolerances, sample size, etc. 

f. An acceptable useful life plan is exemplified in Table 11. 

Table 11.—Useful life plan timeline 

3rd Start 1st Service Date 2nd Service Date -- etc. Stop 

[--------I----------- 1st Service expiration 

---------I-----------

After a completed 

---------I-----------

After a completed 

---------I-----------

After a completed 

-------I > 

Terminal End of 

date permanently 

visible on the unit 

action on each unit 

stamp 2nd service 

action on each unit 

stamp 3rd service 

action, etc. useful life 

date or terminal date date or terminal date 

Note: The date on which the unit must be removed from service is to be 

permanently marked and clearly visible on the unit at the time of manufacture. 

If an incremental service life is granted, the applicant, or their authorized 

representative, must stamp the unit with a new date, as described by the time 

line model. The terminal date represents the final expiration date of the unit 

with no further extensions. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-41 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8.0 Training: 

The applicant will identify training requirements associated with its air-purifying escape 

respirator. As a minimum, the applicant will include an instruction manual, which will address 

donning procedures, respirator use, maintenance (care and useful life), and cautions and 

limitations. The applicant will also provide for training aid systems, to include a training 

respirator that mimics the performance of the approved respirator, such as inhalation and 

exhalation breathing resistance that will develop user proficiency in operation of the equipment, 

as well as identification of periodic refresher training requirements to maintain user proficiency. 

The applicants’ training materials will be used as the basis for preparing the human test subjects 

in the test procedures of paragraph 3.4, Breathing Gas, paragraph 4.7, Laboratory Respirator 

Protection Level, and paragraph 4.9, Donning. 

9.0 Markings and Labels: 

In accordance with the requirements of paragraph 84.33 of 42 CFR, Subpart D, approval labels 

will be marked with a CBRN Rating as determined by paragraph 4.1 Duration Rating, of the 

Statement of Standard for Chemical, Biological, Radiological, and Nuclear (CBRN) Air-Purifying 

Escape Respirator dated September 30, 2003. For example: 

(a) Respirators receiving approval for a 30 minute duration rating are marked: 

ESCAPE ONLY NIOSH CBRN 30. 

(b) Respirators receiving approval for a 30 minute duration rating with carbon monoxide 

protections are marked: 

ESCAPE ONLY NIOSH CBRN 30 with Carbon Monoxide 

(c) Respirators receiving approval for a 30 minute duration rating with a specific category are 

marked: 

ESCAPE ONLY NIOSH CBRN 30 with “chemical” Specific 

(d) Respirators receiving approval for a 30 minute duration, with an specific category, and 

carbon monoxide are marked: 

ESCAPE ONLY NIOSH CBRN 30 with “chemical” Specific and with Carbon Monoxide September 30, 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-42 

2003 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Attachment B 

Statement of Standard 

Chemical, Biological, Radiological, and Nuclear (CBRN) 

Self-Contained Escape Respirator 

1.0 Purpose: 

The purpose of this standard is to specify minimum requirements to determine the effectiveness 

of self-contained escape respirators that address CBRN materials identified as inhalation hazards 

from possible terrorist events for use by the general working population.The respirator must meet 

the minimum requirements identified in the following paragraphs: 

X Paragraph 2.0, Requirements Specified in Title 42, Code of Federal 

Regulations (CFR), Part 84 applicable paragraphs, 

x Paragraph 3.0, Requirements based on existing national and international standards, 

x Paragraph 4.0, Special requirements for CBRN use. 

2.0 Title 42, Code of Federal Regulations (CFR), Part 84: 

The following paragraphs of 42 CFR, Part 84 are applicable: 

2.1 42 CFR, Part 84, Subparts A, B, D, E, F, and G: 

Subpart A: General Provisions Subpart B: 

Application for Approval Subpart D: Approval 

and Disapproval Subpart E: Quality Control 

Subpart F: Classification of Approved Respirators 

Subpart G: General Construction and Performance 

2.2 42 CFR, Part 84, Subpart H: 

Approval under Title 42, CFR, Part 84, Subpart H, for escape only, with a minimum service 

time of 15 minutes. 

3.0 Requirements Based on Existing National and International Standards: 

3.1 Field of View: 

The CBRN self-contained escape respirator will obtain a Visual Field Score (VFS) of 70 or greater 

when tested in accordance with NIOSH Standard Test Procedure CET-APRS-STP-CBRN-0314. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-43 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The VFS will be obtained by using a medium size respirator or equivalent that is sized to fit 

the Head Form described in Figure 14 of EN 136, Respiratory protective devices – Full face 

masks – Requirements, testing, marking; January 1998 or equivalent. 

The VFS is determined by using a VFS grid (Dots on visual field) as defined in the 

American Medical Association Guides to the Evaluation of Permanent Impairment, 

5th Edition (2000) that is overlaid on the diagram of the visual field plot obtained using the 

spherical shell of EN 136 apertometer or equivalent. The VFS score is the average of three 

fittings of the same respirator on the specified head form. 

3.2 Fogging: 

The CBRN self-contained escape respirator will demonstrate an average Visual Acuity 

Score (VAS) of greater or equal to 70 points for all measurements for each individual. A 

minimum of two respirators will be evaluated. 

The respirator will be donned by the test subject in an indoor ambient temperature of 

approximately 72+20F at 40+5% Relative Humidity (RH) and then will enter into a 

simulated outdoor extreme temperature chamber where the visual acuity tests will be 

administered. The self-contained escape respirator will be tested for fogging in the 

hot/humid condition of 90+20F and 60+5% RH and the cold condition of 13+2oF. 

3.3 Breathing Gas: 

Breathing gas criteria will be evaluated as a two-part requirement: 1) a dead-space CO2 

test performed with a breathing machine and 2) carbon dioxide and oxygen 

concentrations during human test subject exercises. The wearer will not experience 

undue discomfort because of restrictions to breathing or other physical or chemical 

changes to the respirator. All trials will be considered as part of the Practical Performance 

criteria of paragraph 4.4. 

3.3.1 Breathing Machine 

The maximum allowable average inhaled carbon dioxide concentration will be less than or 

equal to one percent, measured at the mouth, while the respirator is mounted on a 

dummy head operated by a breathing machine. The breathing rate will be 14.5 

respirations per minute with a minute volume of 10.5 Liters. Tests will be conducted at 

ambient temperature of 25 ± 5°C. A concentration of five percent carbon dioxide in air 

will be exhaled into the facepiece. The minimum allowable oxygen concentration will be 

that of the ambient room oxygen concentration. NIOSH Test Procedure RCT-APR-STP0064 is used for carbon dioxide testing 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-44 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.3.2 Human Subject Testing 

During the testing required by this section, the concentration of inspired carbon dioxide 

gas at the mouth will be continuously recorded, and the calculated maximum range 

concentration during the inhalation portion of the breathing cycle will not exceed the 

limits as stated in Table 1. 

Table 1.—Inspired carbon dioxide limits 

Where the service time is Maximum time-weighted fractional concentration of 

inspired carbon dioxide 

15 min or 30 min 0.025 (or 2.5%) 

45 min or 60 min 0.020 (or 2.0%) 

The inhaled carbon dioxide concentration will be as indicated in the above table. The inhaled 

fractional oxygen concentration will be no less than 0.195 (or19.5%) when 

tested with human subjects at the following work rates: standing and walking at 3.5 miles per 

hour. Two tests (standing and walking at 3.5 miles per hour) will be performed, 

each using 12 test subjects. Table 2 gives face length and width criteria, which the subjects 

will be required to fill. Table 2 is applicable for ‘one size fits all air-purifying escape respirator’ 

or an air-purifying escape respirator with small, medium, and large sizes. For other variations 

in air-purifying escape respirator size, test subjects will be 

determined to provide for panel range of Table 2. 

Table 2.—Test design criteria 

*LANL Boxes – ‘Small’ *LANL Boxes – ‘Medium’ *LANL Boxes – ‘Large’ 

1, 2, 3, 4 3, 4, 5, 6, 7, 8 7, 8, 9, 10 

Four subjects in ‘Small’ 

boxes. More than one 

subject possible in any 

box. 

Four subjects in ‘Medium’ 

boxes. More than one subject 

possible in any box. 

Four subjects in ‘Large’ boxes. 

More than one subject 

possible in any box 

*Adapted from the Los Alamos National Laboratory report respirator test panel 

Each exercise will be performed for 10 minutes. Carbon dioxide and oxygen data will be 

considered for the last five minutes of each exercise. For each of these last five minutes, the 

last five breaths will be considered. 

For each group of 12 subjects, 95% of the total number of trials must meet the stated 

criteria. Should a group of test trials not pass the 95% of trials, one addition run of test trials 

consisting of 12 test subjects may be performed to increase the total number of trials; the 

total number of trials (total of 48) will be the sum of trials from the first and second run of 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-45 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

subjects. All trials will be considered in the Practical Performance requirement criteria of 

paragraph 4.4. 

3.4 Flammability and Heat Resistance: 

Self-contained escape respirators submitted for approval will be tested for Flammability 

and Heat Resistance using the test equipment specified in EN 136, Respiratory Protective 

Devices, Full Face Masks, Requirements, testing, Marking, 1998 Edition, Class 1 facepiece. 

No component of the respirator will have an after flame after five seconds. No component 

of the escape respirator shall drip, melt, or develop a visible hole. 

The distance between the outer surface of the escape respirator and the burner will be 

adjusted to 20 ± 2 mm. The pressure reducer will be adjusted to 2.1 ± .05 psi. The 

temperature of the flame positioned above the burner tip will be 800±500 C at a point 20+2 

mm above the tip. The respirator will be rotated once through the flame at a velocity of 6 ± 

0.5 cm/s. Where components of the respirator such as valves, filters, etc. are arranged on 

the respirator, the test will be repeated with these components at the appropriate height 

of 250 mm ± 6.4 mm. 

3.5 Design Considerations: 

3.5.1 Function: 

The self-contained escape respirator will provide a barrier from ambient conditions for the 

wearer’s entire head, eyes, and respiratory system. The self-contained escape respirator 

will not require the use of hands to maintain the respirator position to ensure proper 

function of the respirator when fully donned. 

3.5.2 Hood Type Devices: 

The self-contained escape respirator will be designed as a hooded device. The hood will 

include an area for field of vision. A hood is a respirator component which covers the 

wearer’s head and neck, or head, neck and shoulders, and is supplied with incoming 

respirable air for the wearer to breathe. 

3.5.3 Respiratory Protection System: 

The respiratory protection system may consist of an oral/nasal cup or mouthpiece. If a 

mouthpiece is employed, a method of preventing nasal breathing must be provided. An 

oral/nasal cup or a mouthpiece is not required provided all requirements of this standard 

are fulfilled by the self-contained escape respirator. 

4.0 Special CBRN Requirements: 

4.1 Duration/Service Life: 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-46 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The self-contained escape respirator will have a minimum service life of 15 minutes. 

4.2 Chemical Agent Permeation and Penetration Resistance Against Distilled Sulfur 

Mustard (HD) and Sarin (GB) Agent Requirement: 

The self-contained escape respirator system, including all components and accessories, will 

resist the permeation and penetration of Distilled Sulfur Mustard (HD) and Sarin (GB) chemical 

agents when tested on an upper-torso manikin. Closed-circuit devices will be connected to a 

metabolic breathing simulator, using the following protocol: 

For a mean VO2 = 1.67 L/min for 30 minutes (aggregate VO2 = 50 L/minTime) 

VO2 VCO2 Minute Ventilation Resp.rate 

Min L/min, STPD L/min, STPD L/min, STPD b/min 

0-5 3.0 3.2 65 25 

6-20 2.0 1.8 44 20 

21-30 0.5 0.4 20 12 

For open-circuit devices, a breathing machine will be used, operating at an airflow rate of 

19.5 Lpm,18 respirations per minute, 1.1 Liters tidal volume. 

Test requirements for Distilled Sulfur Mustard (HD) are shown in Table 3. 

Table 3.—Vapor-Liquid Sequential Challenge of Self-contained Escape Respirator 

with Distilled Sulfur Mustard (HD) 

Agent Challenge Duration of Breathing Maximum Maximum Number Minimum 

Concentration Challenge Machine Peak Breakthrough of Service Life 

(min) Airflow 

Rate 

Excursion 

(mg/m3) 

(concentration 

integrated 

Systems 

Tested 

(hours) 

(Lpm) over minimum 

service life) 

(mg-min/m3) 

HD Vapor 300mg/m Stated Duration 

HD Liquid .50ml Stated Duration 19.5 0.60 6.0 3 Stated Duration 

* Vapor challenge concentration will start immediately after the liquid drops have been applied and the test 

chamber has been sealed. 

†Liquid volume is applied as 25 drops of equal size. 

‡ Three consecutive sequential test data points at or exceeding 0.6 mg/m3 will collectively constitute a failure where 

each test value is based on a detector sample time of approximately two minutes. 

§ The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of the 

test. 

** Duration of challenge is equal to applicant’s identified duration. 

†† Minimum Service Life is equal to twice the applicant’s identified duration. 

‡‡ Respirators will be monitored in the oral/nasal and ocular regions 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-47 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Test requirements for Sarin (GB) agent are shown in Table 4. 

Table 4.—Vapor Challenge of Self-Contained Escape Respirator with Sarin (GB) 

Challenge Vapor Vapor Breathing Maximum Maximum Number Minimum 

Concentration Concentration Challenge Machine Peak Breakthrough of Service 

(mg/m3

) Time Airflow Excursion (concentration Systems Life 

(minutes) Rate mg/m3 integrated Tested (hours) 

(Lpm) over minimum 

service life) 

(mg-min/m3) 

0.9 for 

durations less 

than 30 

minutes 

Total CT of Stated Stated 

GB 10,000mg-m3 $ Duration*, 19.5 0.087‡ 3 Duration†, 

** †† 2.1 for 

durations 

greater than 30 

minutes§,‡‡ 

* The vapor challenge concentration generation will be initiated immediately after test chamber has been 

sealed. 

† The test period begins upon initial generation of vapor concentration. 

‡ Three consecutive sequential test data points at or exceeding 0.087 mg/m3 will collectively constitute 

a failure where each test value is based on a detector sample time of approximately two minutes. 

§ The cumulative Ct including all maximum peak excursion data points must not be exceeded for the 

duration of the test. 

** Duration of challenge is equal to applicant’s identified duration 

†† Minimum Service Life is equal to the applicant’s identified duration. 

‡‡ Respirators will be monitored in the oral/nasal and ocular regions 

$ Exposure will include at least two minutes at a concentration of 2000 mg-m3 

4.3 Laboratory Respiratory Protection Level (LRPL) Test Requirement: 

The measured laboratory respiratory protection level (LRPL) for each air-purifying escape 

respirator will be 3000 or greater, for 95% of trials, sampled in the breathing zone of the 

respirator, and will be 150, or greater, for 95% of trials, sampled outside the breathing zone 

(under the hood). Each trial must meet the breathing zone criteria and ‘under the hood’ criteria 

simultaneously for the trial to be considered passing. Test subject and replication numbers are 

outlined in Table 5. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-48 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 5.—Anthropometric test criteria 

Small Medium Large 

Face Length 

and 

Face Width 

Cell A 

Use LANL boxes 1, 2, 3, 

4 (2 or 3 subjects each 

box, 2 trials per subject) 

Subjects= 10 

Trials= 20 

Cell D 

Use LANL boxes 3, 4, 5, 6, 7, 

8; panel size 17 (2 or 3 

subjects each box, 2 trials per 

subject) 

Subjects= 17 

Trials= 34 

Cell G 

Use LANL boxes 7, 8, 9, 10; 

panel size 11 (2 or 3 subjects 

each box, 2 trials per subject) 

Subjects= 11 

Trials= 22 

Head 

Circumference 

Cell B 

N/A 

Subjects= 0 

Trials= 0 

Cell E 

N/A 

Subjects= 0 

Trials= 0 

Cell H 

570-603 mm 

Subjects= 10 

Trials= 20 

Neck 

Circumference 

Cell C 

306-378 mm 

Subjects= 10 

Trials= 20 

Cell F 

355-403 mm 

Subjects= 10 

Trials= 20 

Cell I 

378-451 mm 

Subjects= 10 

Trials= 20 

The respirator is tested in an atmosphere containing 20-40 mg/m3 corn oil aerosol of a mass 

median aerodynamic diameter of 0.4 to 0.6 micrometers. Should a group of test subjects 

result in LRPL trials where less than 95% of trials have passing results, one additional run of 

test subjects that fills the entire anthropometric panel requirements may be performed to 

increase the total number of trials; the total number of trials will be the sum of trials from 

the first and second run of subjects. All trials will be considered in the Practical Performance 

requirement criteria of paragraph 4.4. The LRPL will be calculated using nine exercises: 

Normal Breathing, Deep Breathing, Turn Head Side to Side, Move Head Up and Down, Reach 

for the Floor and Ceiling, On Hands and Knees - Look Side to Side, Facial Grimace, Climb Stairs 

at a Regular Pace, and Normal Breathing. 

For each size category (Small, Medium, and Large), each cell corresponding to the 

anthropometric parameter will be tested. Cells can be either consecutively (if the test 

subjects only meet the requirements of a specific cell) or concurrently (if the test subjects 

meet the requirements of more than one cell) tested for each size category. 

4.4 Practical Performance: 

The Practical Performance of the air-purifying escape respirator will be evaluated as part 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-49 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of the test procedures of paragraphs 3.4, Breathing Gas, and 4.7, Laboratory Respirator 

Protection Level. The Practical Performance of the respirator will evaluate human 

interface issues associated with the use of the escape respirator. As a minimum, 

contributing factors (if applicable based upon the respirator design) are: the use of mouth 

bits and nose clips; seal of the hood around the respirator wearer’s neck; seating of inner 

masks; position of the hood on the respirator wearer’s head; and strength required to don 

the respirator. Test subjects will be trained on proper use of the escape respirator in 

accordance with the applicant’s instructions identified in paragraph 8.0, Training. Inability 

of any test subject participating in the test procedures of paragraphs 3.3, Breathing Gas, 

and 4.3, Laboratory Respirator Protection Level, to complete the test procedures will 

constitute a failure of the Practical Performance requirement for that trial. 

Practical Performance trials will be accumulated from the test procedures of paragraphs 

3.3, Breathing Gas, and 4.3, Laboratory Respirator Protection Level. For the total of these 

accumulated trials, 95% of these trials will exhibit acceptable Practical Performance. 

Should 95% of the Practical Performance test trials not be acceptable, one additional run 

of test trials consisting of either, or both, paragraph 3.3, Breathing Gas, or paragraph 4.3, 

Laboratory Respirator Protection Level, may be performed to increase the total number of 

trials. The total number of trials will be the sum of trials from the first and second run of 

subjects. 

4.5 Donning: 

The time to don the self-contained escape respirator from the ready-to-use configuration 

will be no greater than 30 seconds. The ready to use configuration is the operational 

packaging state prior to use such that immediately upon opening allows the user to don 

the respirator. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-50 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.6 Environmental Conditioning Requirements: 

Environmental, vibration, and drop conditioning will be performed on the self-contained escape 

respirators in the ready-to-use configuration. The ready-to-use configuration is 

the operational packaging state prior to use, such that immediately upon opening allows the user to 

don the respirator. Respirators will be visually inspected following environmental conditioning to 

ensure no damage or deterioration has occurred that could negatively affect the intended use of the 

respirator. 

Environmental conditioning will be performed in accordance with Table 6. 

Table 6.—Environmental Conditioning 

Test Test Method Test Condition Duration 

Hot Constant Mil-Std-810F 

Method 501.4 0 0 71 C (160 F), Constant 5 Weeks 

Cold Constant 

Mil-Std-810F, 

Method 502.4 

0 0 Basic Cold, -32 C (-24 F); 

Constant 3 Days 

Humidity Mil-Std-810E, 507.3; 

Realistic, Natural Cycle 

Humidity Profiles in the 

U.S. 

5 Days, “Quick Look” 

Mil-Std-810E Table 

507.3-II 

Transportation/Vibration Mil-Std-810F, 514.5 

US Roadway Vibration, 

Unrestrained 

12 Hours/Axis, 3 Axis; 

Total Duration =36 

Hours, equivalent to 

12,000 miles 

Drop Standard Drop Test Height of 3 feet 1 drop on each of the 3 

Axes per Unit. 

4.7 Test Sequence and Quantity: 

Testing of the self-contained escape respirator shall follow Table 7. 

Table 7.—Test Sequence and Quantity 

Test 

Order 

Breathing 

Gas

† Human 

Factors 

Penetration 

and 

Permeation 

Testing 

LRPL 

Test † 

Qty 24. 5-11 6 systems * 30-65 

1. 

Breathing 

Gas 

Para 3.3 

Donning 

Para 4.5 

Hot 

Constant 

Para 4.6 

LRPL 

Para 4.3 

2 

Practical 

Performance 

Para 4.4 

Fogging 

Para 3.2 

Cold Constant 

Para 4.6 

Practical Performance 

Para 4.4 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-51 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3 

Field of 

View 

Para 3.1 

Humidity 

Para 4.6 

4 

Flammability 

and Heat 

Resistance 

Para 3.4 

Transportation/ 

Vibration Para 

4.6 

5 Drop 

Para 4.6 

6 

System 

Testing 

Para 4.2 

* A total six systems tests are performed, 3 GB and 3 HD. Two systems tests, 1 GB and 1 HD, are performed prior 

to Para. 4.6 Environmental Conditioning. Four systems tests, 2 GB and 2 HD, are performed after Para. 4.6 

Environmental Conditioning. 

† Breathing Gas and LRPL are performed prior to Paragraph 4.6, Environmental Conditioning. 

5.0 Quality Assurance Requirements: 

5.1 Quality Control Plan: 

Respirators submitted for CBRN approval will be accompanied by a complete quality control plan 

meeting the requirements of Subpart E of Title 42, CFR, Part 84. 

5.2 Sampling/Test/Inspection Plan: 

The applicant will specify a sampling/test/inspection plan for respirator parts and materials to 

ensure the construction and performance requirements of this standard are established 

through the manufacturing process. As a minimum, specific attributes to be addressed are: 

a) Materials of construction used for respirator parts that form a barrier between the 

user and ambient air. 

b) Integrity of mechanical seals that comprise a barrier between the user and ambient 

air. 

6.0 General Requirements: 

In addition to the requirements of Title 42, CFR, Subpart G – General Construction and 

Performance Requirements, the following requirements apply: 

Prior to making or filing any application for approval or modification of approval, the applicant 

will conduct, or cause to be conducted, examinations, inspections, and tests of respirator 

performance, which are equal to or exceed the severity of those prescribed in the standard. 

Chemical Agent Penetration and Permeation Resistance Against Distilled Sulfur Mustard (HD) 

and Sarin (GB) tests, Paragraph 4.2, are excluded from this requirement. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-52 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7.0 Useful Life and Maintenance: 

The applicant will identify an initial useful life, not to exceed five (5) years, of the escape 

respirator. The “useful life” is defined as the length of time a unit can remain deployed in the 

‘ready to use’ stowed condition. All applications for certification must specify useful service life 

with supporting data and rationale. Further, a rationale must be included for any sampling plan 

set forth in the user instructions which would extend the useful life of the escape respirator 

beyond any initial useful life. However, extensions of useful life will be determined during the 

last year of the initial useful life. 

The following guidelines should be included in the useful service life plans: 

a. Useful life plans should be based upon reliability engineering methodology and describe 

the conditions for use for the unit. Each plan will be individually evaluated. 

b. All respirator service actions are the responsibility of the applicant, or their 

authorized representative. The user/owner of the respirators should perform basic 

inspections as described in the instruction manual and/or as required by federal 

regulations. 

c. In order for an escape respirator to receive an incremental useful life extension, 

some service action must be performed on each unit. 

d. After the service action has been performed, the applicant, or their authorized 

representative, should collect a random sample of the serviced units and performance 

test these respirators to verify that they function as approved. The purpose of postservice sampling and performance testing is to identify unexpected problems caused by 

uncontrolled or unpredicted factors. 

e. The applicant may define “performance testing” by specifying the following: 

test procedures, pass/fail standards, performance tolerances, sample size, etc. 

f. An acceptable useful life plan is exemplified in Table 8 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-53 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 8.—Useful life plan timeline 

Start 

[--------I----------- 1st Service expiration 

date permanently 

visible on the unit 

1st Service Date 

---------I-----------

After a completed 

action on each unit 

stamp 2nd service 

date or terminal date 

2nd Service Date 

---------I-----------

After a completed 

action on each unit 

stamp 3rd service 

date or terminal date 

3rd -- etc. 

---------I-----------

After a completed 

action, etc. 

Stop 

-------I-> 

Terminal End of 

service life 

Note: The date on which the unit must be removed from service is to be 

permanently marked and clearly visible on the unit at the time of manufacture. 

If an incremental service life is granted, the applicant, or their authorized 

representative, must stamp the unit with a new date, as described by the time 

line model. The terminal date represents the final expiration date of the unit 

with no further extensions. 

8.0 Training: 

The applicant will identify training requirements associated with its air-purifying 

escape respirator. As a minimum, the applicant will include an instruction manual, 

which will address donning procedures, respirator use, maintenance (care and useful 

life), and cautions and limitations. The applicant will also provide for training aid 

systems, include a training respirator that mimics the performance of the approved 

respirator, such as inhalation and exhalation breathing resistance that will develop 

user proficiency in operation of the equipment, as well as identification of periodic 

refresher training requirements to maintain user proficiency. The applicants’ training 

materials will be used as the basis for preparing the human test subjects in the test 

procedures of paragraph 3.3, Breathing Gas, paragraph 4.3, Laboratory Respirator 

Protection Level, and paragraph 4.5, Donning. 

9.0 Markings and Labels: 

NIOSH will authorize the use of an additional approval label on the self-contained escape 

respirator that demonstrates compliance to the CBRN criteria. This label is to be placed 

in a visible location. The addition of this label will provide visible and easy identification of 

equipment for its appropriate use. In accordance with the requirements of paragraph 

84.33 of 42 CFR, Subpart D, approval labels will be marked with a CBRN Rating as 

determined by paragraph 4.1 Duration/Service Life Rating. For example, respirators tested 

for 15 minutes are marked ESCAPE ONLY NIOSH CBRN 15. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-54 
 

 

 

Self-Contained Breathing Apparatus (SCBA) 

with CBRN Protection 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-55 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Attachment A 

Statement of Standard 

The SCBAs must meet the following minimum requirements: 

• Approval under NIOSH 42 CFR Part 84, Subpart H 

• Compliance with National Fire Protection Association (NFPA) Standard 

1981 for Open-Circuit Self-Contained Breathing Apparatus for Fire 

Fighters 

• Special Tests under NIOSH 42 CFR 84.63(c) 

(1) Chemical Agent Permeation and Penetration Resistance 

Against Distilled Sulfur Mustard (HD) and Sarin (GB) (2) 

Laboratory Respirator Protection Level (LRPL) 

(1). Chemical Agent Permeation and Penetration Resistance Against Distilled 

Mustard (HD) and Sarin (GB) Agent Test Requirement 

Open-circuit, positive-pressure SCBAs, including all components and accessories except the 

air cylinder (shell), will resist the permeation and penetration of distilled sulfur mustard 

(HD) and sarin (GB) chemical agents when tested on an upper-torso manikin connected to 

a breathing machine operating at an airflow rate of 40 liters per minute (L/min), 

36 respirations per minute, 1.1 liters tidal volume. 

Test requirements for distilled sulfur mustard (HD) are shown in Table 1. 

Table 1: Simultaneous Liquid and Vapor Challenge of SCBA with Distilled Sulfur Mustard 

(HD) 

Agent Challenge 

Concentration 

Duration 

of 

Challenge 

(min) 

Breathing 

Machine 

Airflow 

Rate 

(L/min) 

Maximum 

Peak 

Excursion 

(mg/m3

) 

Maximum 

Breakthrough 

(concentration 

integrated 

over Minimum 

Service Life) 

(mg-min/m3) 

Number 

of 

System s 

Tested 

Minimum 

Service 

Life 

(hours) 

HD-Vapor 300 mg/m

3 30 (1) 

40 0.60 (3) 6.0 (4) 3 6 (2) 

HD-Liquid 0.86 ml 360 

(1) Vapor challenge concentration will start immediately after the liquid drops have been 

applied and the test chamber has been sealed. 

(2) The test period begins upon start of initial vapor generation. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-56 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(3) Three consecutive sequential test data points at or exceeding 0.6 mg/m3 will collectively 

constitute a failure where each test value is based on a detector sample time of 

approximately two minutes. 

(4) The cumulative Ct including all peak data points must not be exceeded for the duration 

of the six-hour test. 

Test requirements for sarin (GB) agent are shown in Table 2. 

Table 2: Vapor Challenge of SCBA with Sarin (GB) 

Challenge 

Agent 

Vapor 

Concentration 

(mg/m3) 

Vapor 

Challenge 

Time 

(minutes) 

Breathing 

Machine 

Airflow 

Rate 

(L/min) 

Maximum Peak 

Excursion 

mg/m3 

Maximum 

Breakthrough 

(concentration 

integrated over 

Minimum 

Service Life) 

(mg-min/m3) 

Number 

of 

Systems 

Tested 

Minimum 

Service Life 

(hours) 

GB 2,000 mg/m3 30 (1) 40 0.087 (3) 2.1 (4) 3 6 (2) 

(1) The vapor challenge concentration generation will be initiated immediately after 

test chamber has been sealed. 

(2) The test period begins upon initial generation of vapor concentration. 

(3) Three consecutive sequential test data points at or exceeding 0.087 mg/m3 will 

collectively constitute a failure where each test value is based on a detector sample 

time of approximately two minutes. 

(4) The cumulative Ct including all peak data points must not be exceeded for the duration 

of the six-hour test. 

(2). Laboratory Respiratory Protection Level (LRPL) Test Requirement 

The measured laboratory respiratory protection level (LRPL) for each open-circuit positivepressure self-contained breathing apparatus will be >500, when the SCBA facepiece is 

tested ina negative pressure mode inan atmosphere containing 20-40 mg/m3 corn oilaerosol 

of a mass median aerodynamic diameter of 0.4 to 0.6 micrometers. 

APPENDIX A - CBRN RESPIRATOR STANDARDS | A-57 
 

 

 

 

APPENDIX B 

OSHA CBRN FIT TESTING INTERPRETATION LETTER 

Appendix B – 

OSHA CBRN Fit Testing 

Interpretation Letter 

APPENDIX B – OSHA CBRN Fit Testing Interpretation Letter | B-1 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U.S. Department of Labor OccupationalSafety and Health Administration 

Washington,D.C.20210 

Reply to the attention of: DEC 27, 2011 

James S. Johnson, PhD JSJ 

and Associates 

7867 Cypress Creek Court 

Pleasanton, CA 94588 

Dear Dr. Johnson: 

Thank you for your July 6, 2011, letter to the Occupational Safety and Health Administration's 

(OSHA) Directorate of Enforcement Programs. You requested an interpretation of the fit testing 

requirements in the Respiratory Protection Standard, 29 CFR 1910.134. Your paraphrased 

question and our response are below. This response constitutes OSHA's interpretation only of 

the requirements discussed and may not be applicable to other scenarios and questions. 

Scenario: There is some confusion about the fit-testing requirements that apply to NIOSHcertified respirators for chemical, biological, radiological,and nuclear (CBRN) protection. 

Many respirator manufacturers include requirements in their user instructions for users to achieve 

a fit factor up to 2500 using a quantitative fit test (QNFT), if the respirator is to be used for a CBRN 

application. The types of CBRN respirators currently available are self-contained breathing 

apparatus (SCBAs), powered air-purifying respirators (PAPRs), and air-purifying 

respirators (APRs) with canisters. All respirators that require fit testing are equipped with a full 

facepiece. The Respiratory Protection Standard 's requirements for fit testing, as summarized in 

Table 1 of OSHA Directive CPL 02-00-120, Inspection Procedures for the Respiratory Protection 

Standard, permits either qualitative or quantitative fit testing methods to be used for some full 

facepiece respirators. 

Question: Which protocol does OSHA require for fit testing CBRN respirators? 

Response: Workers wearing full facepiece air-purifying respirators must achieve a fit factor of at 

least 500 when using an OSHA-accepted quantitative fit test protocol. OSHA's Respiratory 

Protection Standard, 29 CFR 1910.134, does not treat CBRN full facepiece respirators 

differently from other full facepiece respirators. The standard designates an assigned protection 

factor (APF) of 50 for full facepiece air-purifying respirators. The standard requires all workers who 

are required to wear them to be fit tested using an OSHA-accepted QNFT protocol and receive a fit 

factor of 500 or greater to pass. While a manufacturer's recommendation for a pass level of 2000 

or 2500 would provide an added safety factor when fit-testing their respirators, obtaining such a fit 

factor does not increase the assigned protection factor for that respirator, nor does it allow the use 

of the respirator in a more toxic atmosphere. When enforcing this standard, OSHA would still 

require that these tight-fitting full facepiece respirators achieve the minimum pass level of 500 

when using QNFT as provided in paragraph 191 0.134(f)(7). OSHA also would allow a manufacturer's 

higher pass level to be used. 

APPENDIX B – OSHA CBRN Fit Testing Interpretation Letter | B-2 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

- 2-

For fit testing tight-fitting atmosphere-supplying respirators and tight-filling PAPRs, paragraph (f)(8) 

allows employers to use either quantitative or qualitative fit testing (QLFT) methods with the 

respirator in a negative pressure mode. As previously mentioned, if the QNFT protocol is used, OSHA 

requires the minimum pass level of 500 for QNFTs provided for in paragraph 

191 0.134(f)(7) for these tight-fitting full facepiece respirators, but also would allow a 

manufacturer's higher pass level to be used. 

OSHA allows the use of QLFT for testing tight-fitting atmosphere-supplying respirators and tightfitting PAPRs with the respirator tested in the negative pressure mode. These respirators will be 

used in a positive pressure or pressure demand mode in the workplace, and QLFT will determine 

whether the worker can get a reasonably good fit with the facepiece. This testing procedure 

ensures the mask is capable of maintaining a positive pressure inside the facepiece during work 

activities and any leakage would be from inside the mask to the outside. 

As you are located in California, you should be aware that the California Department of Industrial 

Relations, Division of Occupational Safety and Health (Cal/OSHA), operates an OSHA-approved State 

Plan that is responsible for the adoption and enforcement of standards throughout the State. State 

Plans are required to set workplace safety and health standards that are at least as effective as the 

comparable Federal standards. Information on the Cal/OSHA program is available at 

http://vvww.osha.gov dcsp/osp/stateprogs california.html. Please contact Cal/OSHA directly for 

further information and to discuss your specific compliance situation: 

Ellen Widess, Chief 

Division of Occupational Safety and Health 

1515 Clay Street Suite 1901 

Oakland, CA 94612 

PH: (51 0) 286-7000 

FAX: (510) 286-7037 

Thank you for your interest in occupational safety and health. We hope you find this 

information helpful. OSHA requirements are set by statute, standards, and regulations. Our 

interpretation letters explain these requirements and how they apply to particular circumstances, but 

they cannot create additional employer obligations. This letter constitutes OSHA's interpretation of 

the requirements discussed. Note that our enforcement guidance may be affected by changes to 

OSHA rules. Also, from time to time we update our guidance in response to new information. To 

keep apprised of such developments, you can consult OSHA's website at www.osha.gov. If you have any 

further questions, please feel free to contact the Office of Health Enforcement at (202) 693-2190. 

Sincerely, 

Thomas Galassi, Director 

Directorate of Enforcement Programs 

cc: cc: Region IX, Cat/OSHA, DCSP 

APPENDIX B – OSHA CBRN Fit Testing Interpretation Letter | B-3 
 

APPENDIX C 

RESPIRATORY PROTECTION PROGRAM SAMPLES

Appendix C –

Respiratory Protection 

Program Samples 

Appendix C Respiratory Protection Program Sample | C-1 
 

 

Sonoma County 

Fire and Emergency Services Department 

Sonoma County, CA 

Appendix C Respiratory Protection Program Sample | C-2 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 1 of 4 

PROCEDURE MANUAL Code: 2-8-2 

Safety Program 

Respiratory Protection Program 

Original Date:2005 Revised Date:2/20/11 

2.01 PURPOSE 

To establish rules, procedures, and guidelines relative to respiratory protection that reflects 

the Sonoma County Fire and Emergency Services Department (County Fire) commitment to 

the safety and well being of our members and compliance with CAL/OSHA Title 8, Section 

5144. 

2.02 SCOPE 

All County Fire paid and volunteer staff 

2.03 POLICY 

County Fire is committed to maintaining an injury free workplace, and making every effort to 

protect our members from harmful airborne substances. We accomplish this through 

engineering controls such as air monitoring and ventilation and through administrative controls 

limiting the duration of exposure. When these methods are not adequate, we provide 

respirators to allow members to breathe safely in potentially hazardous environments. 

We recognize that respirators have limitations and their successful use is dependant upon an 

effective respiratory protection program. This Respiratory Protection Program is designed to: 

identify, evaluate, and control exposure to respiratory hazards; select and provide the 

appropriate respirators; and coordinate all aspects required for proper use, care, and 

maintenance of the equipment. 

2.04 PROCEDURES 

1. Program Administration: 

County Fire will provide leadership by example and ensure that adequate resources are 

available for effective implementation of our Respiratory Protection Program. We expect and 

require all members to work conscientiously to carry out our Respiratory Protection Program, 

which is an element of our Injury and Illness Prevention Program. The County Fire Safety Officer 

is the program administrator who has the authority and responsibility for overall management 

and administration of our Respiratory Protection Program, which consists of the following: 

a. Preparing, evaluating, and modifying the written respiratory protection program 

b. Identifying, locating, and maintaining ongoing surveillance and evaluation of airborne 

exposures 

c. Selecting respirators 

d. Conducting medical screening for potential respirator users 

e. Conducting respirator fit testing and assignment 

f. Training 

g. Record keeping 

To assist the program administrator, certain aspects of the program will be delegated to others 

3/8/11 

Appendix C Respiratory Protection Program Sample | C-3 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 2 of 4 

within County Fire. All supervisors are responsible for members under their supervision. 

2. Program Implementation and Evaluation 

Our Respiratory Protection Program begins with this written plan describing the procedures that 

we practice. Suggestions and comments from employees and volunteers about exposure 

conditions, respirators, personal health changes, and training issues will be addressed promptly. 

3. Workplace Exposure Assessment and Ongoing Surveillance 

Our first task in the workplace is an exposure assessment to identify harmful airborne 

contaminants and document their extent and magnitude, and how to control them. We must ensure 

that employee exposure does not exceed the permissible concentrations specified in the California 

Code of Regulations Title 8, Section 5155. This requires the department’s Safety Officer to 

evaluate the policies and procedures and conduct exposure monitoring. We conduct air monitoring 

at Hazardous Materials incidents and at fires to ensure that contaminants are identified and that 

concentrations do not exceed the published PELs. Additional evaluations are necessary if 

exposures change due to new materials, operational changes, or other conditions increasing the 

degree of exposure or stress. 

4. Respirator Selection 

In those instances where engineering and administrative means do not achieve the desired control, 

or in the case of an emergency, respirators MUST be worn. Different types of respirators are 

available for a variety of applications and we must ensure that the proper NIOSH/MSHA approved 

respirator is selected and used for the kind of work being performed and hazards involved. 

Given the type of environment, operations, and response our personnel participate in, the 

following types of respiratory protection are available: 

a. Self-contained positive pressure breathing 

apparatus b. Air-Purifying Respirators 

c. HEPA filter respirator (N95) and (P100) 

All unknown products will be considered an IDLH environment requiring Positive Pressure SelfContained Breathing Apparatus (SCBA). 

5. Evaluating Respirator Wearer Health Status 

Even with the appropriate equipment and adequate training provided, health status must be 

considered before allowing respirator use. The wearer’s physical condition, duration and 

difficulty of the task, toxicity of the contaminant, and type of respirator all affect the employee’s 

ability to wear a respirator while working. Also, respirators are uncomfortable and may reduce 

the wearer’s field of vision. Therefore, there is a medical evaluation to assess the employee or 

volunteer’s ability to work while wearing a respirator. 

Each member will be provided with the physical status questionnaire packet consisting of the 

following: 

a. OSHA Respirator Medical Questionnaire 

b. An envelope addressed to the Department’s Designated Physician marked Confidential and 

affixed with the appropriate postage 

c. A referral for medical evaluation 

This packet is to be completed and forwarded to the Occupational Health Physician. Members will 

not wear respirators of any type during emergency activities until the Department has received the 

Appendix C Respiratory Protection Program Sample | C-4 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

appropriate clearance from the Occupational Health Physician. These forms will be updated annually. 

6. Respirator Fit Testing & Assignment 

Following completion of the mandatory medical questionnaire and selection of the appropriate 

type of respirator, each member will participate in a qualitative fit test; the purpose of which is to 

determine the best fitting facepiece, model, and size for the member. 

Hazardous Materials Emergency Response Team members will participate in a quantitative fit 

testing procedure due to the type of response they are assigned to. 

Fit testing and respirator selection will be conducted consistent with CAL/OSHA Title 8, Section 

5144, Appendix A, and will be conducted upon appointment and annually thereafter. 

The form “Respirator Fit Testing and Assignments” (Appendix 2) will be used to document fit 

test results and respirator assignment. This form will be maintained in the member’s personnel 

and training records. 

Members who have facial hair that comes between the sealing surface of the facepiece and the 

face, or that interferes with the valve function; or any condition that interferes with the faceto-face piece seal or valve function, shall not be fit tested. In addition, it will be the 

responsibility of the responder and the Chief to ensure that at no time will a member with 

facial hair be allowed to don a respirator and therefore will be excluded from any response 

requiring respiratory protection. 

Any member that is not fit tested and subsequently medically cleared for respirator use, will not 

participate in any activity requiring respiratory protection or activities with the potential for 

requiring respirator use. This shall include any structure fire interior attack, vehicle fire attack, 

structure fire back up team and/or Rapid Intervention Crew (RIC), hazardous materials response, 

medical response, etc. Members will be defined as any County Fire paid or volunteer personnel, 

who may have to don and place in operation any type of respiratory protective devise. 

7. Training 

Once the member is fitted with the correct respirator for the task, the County Fire Training Officer 

will ensure he/she is thoroughly trained in the need, use, limitations, inspection, fit checks, 

maintenance, and storage of the equipment. Ordinarily this training is initiated during the fit test 

and will be completed in accordance with Appendix E of the CAL/OSHA “Guide to Respiratory 

Protection.” 

The manufacturer provides detailed instructions for the use and care of the respirator with the 

equipment. This information is to be used in the training. Each employee required to wear a SelfContained Breathing Apparatus will meet or exceed the training as outlined in the State of 

California Fire Fighter I program for Self-Contained Breathing Apparatus. At a minimum, annually 

each employee will demonstrate their competency by manipulative skills and written testing. The 

manufactures Training Guidelines for M.S.A. Self-Contained Breathing Apparatus will be used as 

reference for all training standards pertinent to SCBA use/maintenance. 

Appendix C Respiratory Protection Program Sample | C-5 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8. Air Manufacturing Program 

County Fire will meet the standards set forth in the OSHA “A Guide to Respiratory 

Protection at Work,” (Air Quality). Also see compressed Air Quality Program below. 

9. Record Keeping 

The County Fire Safety Officer will document each major component of our program to: 

a. Verify that each activity has occurred 

b. Evaluate the success of the program 

c. Satisfy regulatory requirements 

These records include the written program, exposure determination, respirator selection, 

physical status evaluation, a fit testing and respirator assignment, training form, and program 

assessments. 

10. Compressed Air Quality Program 

County Fire is committed to maintaining its compressed air quality program and meeting all 

codes and requirements. 

a. County Fire cooperates with the Windsor Fire Protection District in the 

operation of a high-pressure air compressor and maintains a compressor with 

a cascade system on the Rehabilitation unit to refill compressed air cylinders. 

Any other compressors used via cooperative agreements with other fire 

departments must be maintained and operated per OSHA requirements. The 

member refilling the cylinder is responsible to ensure the compressor is in 

compliance with subsection d. 

b. All members assigned to fill SCBA bottles are trained in the safe and proper 

operation of the compressor. 

c. County Fire has an agreement with TRI Environmental as our maintenance contractor. TRI 

Environmental will conduct, on a semi-annual basis, all scheduled preventative 

maintenance. When non-scheduled repairs are needed the County Fire Materials Handler 

will notify TRI Environmental as soon as possible to conduct the repair. 

d. Air compressors will, at a minimum, be tested for air quality on a quarterly basis. The test 

will be done in accordance with the testing lab’s requirements. The air samples weill be 

sent to TRI Environmental where staff will notify the FESD Safety Officer if test deficiencies 

are found. The lab will notify the tester on record immediately. If no problems are found 

with the sample, the lab will mail a certification of the test taken, which will be kept on file 

at the Windsor Fire Protection District. A copy of the verification will be sent to the County 

Fire Safety Officer. All air tests, at a minimum, will meet the criteria set forth in CGA G7.1 

and NFPA Std, 5-34.1 for grade E air. 

e. Scheduled preventative maintenance will be done on a six month cycle and will include at 

a minimum; filter changes, oil change if needed (100 hrs), and check control system valves. 

as outlined in the maintenance contract. 

f. All maintenance will be logged on the form Semi-Annual Compressed Air Quality 

Report, (Appendix 9). 

2.05 REFERENCES 

Cal/OSHA Title 8, Section 5144 

Appendix C Respiratory Protection Program Sample | C-6 
 

 

 

 

 

 

 

 

 

County of Sonoma 

FIRE & EMERGENCY SERVICES DEPARTMENT 

FIRE SERVICES * EMERGENCY MANAGEMENT "' HAZARDOUS MATERIALS 

MARK ASTON,DIRECTOR/FIRE CHIEF 

March 19, 2012 

James S. Johnson, Ph.D., CIH, QEP JSJ 

and Associates 

7867 Cypress Creek Court 

Pleasanton, CA 94588 

Dear Jim, 

Thank you for requesting permission to use our "Procedure ManualSafety Program, Respiratory 

Protection Program, Code 2-8-2, Respiratory Protection Program," Original Date: 

2005, Revised Date: 2/20/11 in the CDC/NPPTL publication entitled: "CBRN Handbook." With 

appropriate citation we are happy to extend our permission to use this information. 

Please contact us if you have any questions or concerns. 

MA/slt 

Appendix C Respiratory Protection Program Sample | C-7 
 

 

 

Fort Collins Police Services 

Office of Chief of Police, Directive No. D-6 

Fort Collins, CO 

Appendix C Respiratory Protection Program Sample | C-8 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Directive No. D-6 

FORT COLLINS POLICE SERVICES Office of 

the Chief of Police 

General Directive 

Date Issued: March 24, 2009 

Subject: Respiratory Protection Policy 

I. INTRODUCTION 

Because of their unique law enforcement and emergency services roles, many 

Police Services employees are potentially exposed to respiratory hazards during 

routine operations. These hazards include lack of oxygen, harmful concentrations 

of dusts, mists, fumes, smoke, gases, vapors, and, in some cases, represent 

conditions Immediately Dangerous to Life or Health (IDLH). The primary 

objectives of this policy are to preserve the respiratory health of employees and 

to allow employees to safely function in adverse atmospheric environments so 

that they can provide emergency services to citizens and co-workers. While the 

frequency of the need to operate in such adverse environments may be low, the 

need to be able to safely and effectively operate in those environments when 

they do exist is very high from a health and safety standpoint. Fort Collins Police 

Services shall provide appropriate respiratory protection to employees when 

such equipment is necessary to protect the health and safety of the employee 

and the public. 

II. SCOPE 

A. This policy: 

1. Is consistent with the OSHA Respiratory Protection 

Standard, 29 CFR 1910.134. 

2. Applies to: All Police Officers regardless of rank or assignment, all 

Community Service Officers, Criminalists, Forensic Lab Manager, 

and Evidence Technicians. This broad application is necessary 

because at any time, such employees could be required to respond 

to and provide emergency or other crucial services in hostile and 

dangerous 

Appendix C Respiratory Protection Program Sample | C-9 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

environments, regardless of the employees' current rank or 

assignment. 

B. The provisions of this policy are mandatory. Failure to follow the 

provisions of this policy may result in the imposition of discipline up to 

and including termination of employment. 

Ill. MANDATORY ABILITY TO USE RESPIRATORY EQUIPMENT A 

Employees in the following positions, regardless of rank or 

assignment except as specifically noted, must be qualified in the use of 

City-designated respiratory equipment for the following levels of 

protection: 

1. Police Officer - LevelC 

2. SWAT assigned Police Officer other than NegotiatorLevel B 

3. LCDTF assigned Police Officer - Level B 

4. HZMAT assigned Police Officer - Level B 

5. Community Service Officer - Level C 

6. Forensic Lab Manager - Level C 

7. Bomb Squad assigned Police Officer - Level B 

8. Weapons of Mass Destruction Resource Group - LevelBor Level C 

as determined by the Program Administrator depending on the 

duties of the Group member 

9. Criminalist, and Evidence Technician - Level C B. 

The following terms shall have the following meanings: 

1. "Qualified" means to be capable of effectively providing 

emergency and other crucialservices consistent with their 

positions using designated respiratory equipment for the specified 

levels of protection in adverse environments for not less than a 30-

minute continuous period of time. An employee will be 

considered qualified if the employee is deemed medically qualified 

and has achieved an acceptable fit factor for the designated 

respiratory equipment in the 

Appendix C Respiratory Protection Program Sample | C-10 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

specified protection Level. Being qualified is considered an 

essentialfunction of the above positions. 

2. Protection "LevelA" means a respiratory equipment system with 

a totally encapsulating protective suit and includes a selfcontained breathing apparatus (SCBA). 

3. Protection "Level B" means a respiratory equipment system which 

includes a self-contained breathing apparatus (SCBA) but not a 

totally encapsulating protective suit. 

4. Protection "LevelC" means a respiratory equipment system which 

includes a full face respirator with an air filter cartridge (airpurifying). 

C. The designated respiratory equipment issued to an employee may be 

modified or adjusted within a protection Levelif: 

1. It is necessary based on the need of the employee; and 

2. The cost (both in dollars and administratively) of the 

alternative equipment is not unduly burdensome to Police 

Services; and 

3. The employee is able to meet the above use standard with the 

alternative equipment. 

D. Depending upon the needs of Police Services and the availability of 

respiratory equipment,employees may voluntarily become qualified in the 

use of different types of respiratory equipment. 

IV. DETERMINATION OF ABILITY TO USE RESPIRATORY EQUIPMENT A. 

Medical Evaluation 

1. Using respiratory equipment may place a physiological burden on 

an employee that varies with the type of respirator worn,the job, 

workplace conditions, and the medical status 

of the employee. A physician or other licensed health care 

professional(PLHCP) designated by Police Services shall 

determine whether or not an employee has any medical 

conditions that would preclude the use of a respirator in the 

specified protection Level. The PLHCP will consider the guidance 

presented in the American National Standards 

Appendix C Respiratory Protection Program Sample | C-11 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Institute document ANSI Z88.6 in performing medical 

evaluations. 

2. To become qualified in the use of designated respiratory 

equipment within a protection Level, an employee must 

complete a medical history questionnaire approved by the 

Policy Administrator. The Policy Administrator will forward the 

completed questionnaire to the PLHCP for review. 

a. Employees will be permitted to fill out the 

questionnaire during work hours. 

b. Employees who have difficulty interpreting the 

questionnaire may seek clarification from the Policy 

Administrator or his/her designees. 

c. The Policy Administrator will gather the completed 

questionnaire and forward it to the PLHCP in such a 

manner so that the employee's answers are only 

available to the PLHCP. 

3. The PLHCP will review the completed questionnaire to determine 

whether or not the employee appears to be medically qualified for 

the use of the designated respiratory equipment within the 

specified protection Level. The PLHCP may request additional 

information from the employee in making this determination. For 

protection Level A or B, the PLHCP will also gather and consider 

the employee's work history information. 

a. If the PLHCP determines that the employee is 

medically qualified, the PLHC will notify the 

employee and the Policy Administrator. 

b. If the PLHCP is unable to determine that the employee is 

medically qualified, the PLHCP will refer the employee for 

a follow-up medical exam. 

4. The PLHCP conducting the follow-up medicalexam will review 

the medical questionnaire and information provided 

by the Policy Administrator concerning respiratory equipment 

availability, workplace needs, and circumstances under 

which the equipment will be needed. The PLHCP will complete a 

Respirator Certification form providing a written determination 

regarding the employee's ability to be qualified in the use of the 

designated respiratory equipment within the specified protection 

Level and, if applicable, providing any recommendations regarding 

Appendix C Respiratory Protection Program Sample | C-12 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

optional ways for the employee to become qualified. The 

Respirator Certification form will be provided to the employee and 

the Policy Administrator. 

a. The follow-up medical examination may include any 

medical tests, consultations, or diagnostic procedures that 

the PLHCP deems necessary to make a final 

determination. 

b. The employee will be given the opportunity to discuss the 

medical questionnaire and the examination with the PLHCP 

prior to the issuance of a Respirator Certification form that 

does not determine that the employee is medically 

qualified in the use of the designated respiratory 

equipment within the specified protection Level. 

c. The follow-up medical examination shall be conducted 

by a PLHCP chosen by Police Services and at no cost to 

the employee. The examination time will be considered 

compensable time. 

d. The results of the medical examination will be kept 

confidential, except that those management employees 

who have a need to know the results because of their 

responsibility to supervise the employee will have 

access to the results. 

B. Fit Testing 

1. To become qualified in the use of the designated respiratory 

equipment within the specified protection Level, an employee 

must be fit tested before being assigned a respirator and achieve 

an acceptable fit factor for each respirator that will be worn. 

Respirators must fit properly to provide adequate protection 

from hazardous contaminants. 

2. Police Services will make a number of models and sizes of the 

respiratory equipment available within a protection Level in order 

to provide correct fit and to increase the likelihood of employees 

being able to meet the above use standard. 

3. The results of the fit test will be recorded on the Respirator Fit 

Test Record form and will be maintained by the Policy 

Administrator. 

C. Remedial Program 

Appendix C Respiratory Protection Program Sample | C-13 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1. An employee who is determined to be unqualified for medical 

reasons or for a failure to achieve an adequate fit will be 

placed on modified duty. 

2. The Policy Administrator and the employee's supervisor will meet 

with the employee to determine whether or not a remedial 

program can be implemented that is likely to result in 

achievement of the qualification status within six months. The 

goal is to establish a realistic plan that is likely to result in the 

employee becoming qualified as soon as reasonably 

possible. The employee may be re-evaluated for qualification 

at the request of the employee or the Policy Administrator. 

3. If it is determined that the employee is not likely to become 

qualified within six months, has not made a good faith effort to 

follow a remedial program, or has not become qualified within 

six months, the employee's employment may be terminated 

based on the employee's inability to perform an essential 

function of the job. 

4. Under exceptional circumstances, an employee may apply to the 

Director of Human Resources to extend modified duty for up to a 

total of twelve months from the date of being determined to be 

unqualified. The decision whether to grant or deny the request is 

completely within the discretion of the City. 

D. Follow-Up Examination and Testing After Initial Qualification 

1. A fit test will be administered not less than annually and will be 

administered whenever an employee: changes makes, models, 

or sizes of respirators; perceives that the respirator does not seal 

properly; or experiences any condition which alters the 

configuration of the face, e.g., weight change of ten pounds or 

more, broken nose, loss of teeth, or facial surgery. 

2. An employee may also be required to complete a new 

medical history questionnaire, undergo a new medical 

examination, and/or undergo a new fit test if: 

a. The employee reports signs and symptoms related to the 

employee's use of a respirator, such as shortness of breath, 

dizziness, chest pains, or wheezing; or 

b. The Policy Administrator or the employee's supervisor 

reasonably suspects that the employee may no longer be 

qualified. For example, this could be based on observations 

of the employee's fit test, respiratory equipment use, or 

Appendix C Respiratory Protection Program Sample | C-14 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

performance; or 

c. There is a change in the type, model or size of the 

respiratory equipment to be used by the employee; or 

d. Conditions under which the respiratory equipment may be 

used change, thereby increasing substantially the 

physiological burden placed on the employee. 

e. The employee has been exposed to hazardous 

substances at concentrations above the permissible 

exposure limits without the necessary personal 

protective equipment being used. 

V. RESPONSIBILITIES 

A. Policy Administrator: A Police Services lieutenant assigned to the Patrol 

Division is responsible for the administration of this Respiratory 

Protection Policy. This Policy Administrator has the following duties: 

1. Evaluate potentialrespiratory hazards and recommend 

appropriate respiratory protection and other personal 

protective equipment where necessary. 

2. Assist in providing respiratory medical exams, fit tests, and 

selection of appropriate respiratory equipment. 

3. Coordinate with service providers to ensure that employees are 

properly protected from workplace contaminants, including 

advising the service providers of other personal protective 

equipment the employee will be wearing. 

4. Provide the PLHCP with the information required for them to 

conduct respiratory equipment users' medical evaluations. 

Appendix C Respiratory Protection Program Sample | C-15 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5. Review this Respiratory Protection Policy not less than 

annually and recommend revisions to it as necessary to 

ensure that employees are protected from respiratory hazards 

and employees are able to safely and effectively provide 

emergency services in hazardous environments. 

6. Provide employee respiratory protection training and 

administer recordkeeping. 

7. Maintain knowledge of current standard of care with regard to 

respiratory protection and make recommendations for changes 

in equipment and procedures as needed. 

B. Managers and Supervisors: Managers and Supervisors have the 

following duties: 

1. Identify conditions that may require the use of respiratory 

equipment and consult with the Policy Administrator for 

assistance in assessing respiratory hazards. 

2. Ensure that employees receive respiratory medical exams, fit 

tests, and appropriate respiratory equipment before their initial 

use of the respiratory equipment. 

3. Coordinate with Policy Administrator in the medical evaluation, fit 

testing, and selection of respiratory equipment. 

4. Ensure that employees are properly trained and comply with all 

elements of this program, including respiratory equipment 

inspection and maintenance. 

C. Employees: Employees withinthe scope of this Policy have the 

following duties: 

1. Become qualified to use the specified respiratory equipment and 

maintain such qualification. 

2. Contact their supervisorand the Policy Administratorfor 

assistance in evaluating potential hazards that may require 

respiratory protection. 

3. Use the provided respiratory equipment in accordance with 

manufacturer's instructions and provisions of this policy. 

Appendix C Respiratory Protection Program Sample | C-16 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4. Report any malfunction of equipment, concerns with respirator 

fit, or other problems to their supervisor and the Policy 

Administrator. 

5. Clean, inspect, and maintain respiratory equipment in a 

serviceable condition. 

6. Notify his/her supervisor and the Program Administrator of 

changes in their medical status that may impact his/her ability 

to safely use and be qualified to use the specified respiratory 

equipment. 

7. Complete and file with the Program Administrator and the City's 

Risk Management Office a hazardous exposure report any time 

that an employee believes he/she may have been exposed to a 

hazardous substance. 

VI. USE OF RESPIRATORY EQUIPMENT 

A. Only respiratory equipment identified for use in an area or for a 

particular task by the Policy Administrator shall be used. The Policy 

Administrator shall publish a list of such areas/tasks and the appropriate 

respiratory equipment. 

B. Employees who are required to be qualified to wear a tight fitting 

respirator must be clean-shaven where the respirator seal touches the 

face when the respirator is used. Facial hair will also be prohibited when 

it interferes with the function of the valves or the respirator seal. 

C. Employees may use corrective or protective eyewear in a manner that 

does not interfere with the seal of the faceplate of a respirator. Eyewear 

with straps or temple bars that pass through the sealing surface of the 

respirator facepiece shall not be used. The Policy Administrator will 

coordinate acquiring proper eyewear for the employee at the City's 

expense. 

D. Hats, headphones, jewelry, or other articles that may interfere with a 

respirator facepiece seal are not permitted. 

E. To ensure proper sealing, an employee must perform a fit check each 

time the employee wears his/her respirator. 

Appendix C Respiratory Protection Program Sample | C-17 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VII. TRAINING 

A. Prior to use, employees shall be trained in the use and care of 

respiratory equipment. Employees must also receive annual 

refresher training. 

B. Training shall also be conducted whenever: 

1. Changes in the workplace or the type of respiratory 

equipment require new or additional training; 

2. Employees demonstrate that they have not retained the 

requisite understanding or skill; or 

3. Any other situation in which retraining appears necessary to 

ensure safe respiratory equipment use 

C. At a minimum, training shall include: 

1. The importance of respiratory protection 

2. Factors that impair respiratory equipment effectiveness, 

such as poor fit, maintenance, and improper use 

3. Capabilities and limitations of respiratory equipment 

4. Use of respiratory equipment in emergency situations 

5. Inspection 

6. Procedures for donning, doffing, and using respiratory 

equipment 

7. Procedures for checking the seals of the respiratory 

equipment 

8. Maintenance and storage 

9. Recognizing the medical signs and symptoms that may limit or 

prevent the effective use of respiratory equipment 

D. Employees must demonstrate knowledge and skills to satisfy 

training requirements. 

Appendix C Respiratory Protection Program Sample | C-18 
 

 

 

 

 

 

 

 

 

 

VIII. RECORDKEEPING 

A. The Policy Administrator must maintain the following records: 

1. Respiratory equipment certification from the PLHCP 

2. Selection and fit test records 

3. Copy of written respiratory protection policy 

4. Employee training 

5. Hazardous exposure reports 

B. Employees may receive copies of the required records. 

This program has not been reviewed in detail by the author or NIOSH and represents each organization's current 

respiratory protection program. NIOSH takes no responsibility for the content of this respiratory protection program. 

Appendix C Respiratory Protection Program Sample | C-19 
Appendix C Respiratory Protection Program Sample | C-20
 

Promoting productive workplaces 

through safety and health research 

To receive NIOSH documents or more information about 

occupational safety and health topics, contact NIOSH: 

1–800–CDC–INFO (1–800–232–4636) 

TTY: 1–888–232–6348 

CDC-INFO: www.cdc.gov/info 

or visit NIOSH at http://www.cdc.gov/niosh 

For a monthly update on news at NIOSH, subscribe to 

NIOSH eNews at www.cdc.gov/niosh/eNews. 

DHHS (NIOSH) Publication No. 2018-166