Simulated workplace protection factor study of powered air-purifying and supplied air respirators

A study protocol was developed to obtain simulated workplace protection factor (SWPF) data for eleven models of powered air-purifying respirators (PAPRs) and supplied-air respirators (SAR) with hoods and helmets. Respirators were tested in a chamber that allowed the simulation of 12 exercises, including 2 exercises of interest to the pharmaceutical industry. Each respirator was tested by 12 volunteers, and a total of 144 sets of test results were obtained for each device. The testing protocol allowed SWPFs up to 250,000 to be measured (limit of quantification). Median SWPFs for all respirators, except one SAR, were at or above this reporting limit. Lower fifth percentiles were above 100,000, except for one SAR previously noted. An assigned protection factor (APF) was estimated for each respirator by dividing the lower fifth percentile by a safety factor of 25. APFs ranged from 6000-10,000 for PAPRs (including one loose-fitting PAPR) and 3400-10,000 for SARs, with one exception. This SAR had a lower fifth percentile of less than 20 and an estimated APF of 1. Results indicated that most respirators tested could provide a high degree of protection for workers, although one National Institute for Occupational Safety and Health-approved SAR provided minimal, if any, protection. Direct testing in a simulated workplace seems the only method that will assure employers of choosing an adequate SAR. This may be true for other classes of respirators. Furthermore, the historical approach of establishing APFs for classes of respirators, rather than individual models, may not provide adequate protection to the wearer. This is also a serious problem for regulatory agencies seeking to promulgate respirator standard provisions such as APFs for classes of respirators.