Why Respirator Compliance Still Lands in the Top 5 — and What You Must Do

When it comes to industrial safety, respiratory hazards often fly under the radar — unless it's too late. In FY 2025, OSHA issued 1,953 citations under 1926.134, placing Respiratory Protection firmly at #5 on the Top 10 list — despite a significant drop of 906 citations from the previous year.

For safety professionals like Steve, procurement leads like Alex, and operations managers like Pete, this violation underscores an important truth: even when respirators are supplied, the program behind them often falls short. Without fit-testing, medical evaluations, and proper documentation, you’re at risk.

Why Respiratory Protection Is Still a Major OSHA Target

Here are the recurring issues OSHA finds during inspections:

✅ No Written Respiratory Protection Program

OSHA requires a formal program that includes:

• Medical evaluations

• Fit testing (qualitative or quantitative)

• Training on use, limitations, and maintenance

• Periodic evaluation of program effectiveness
  If your site has respirators but lacks this program, you're prone to citation.

✅ Missing or Expired Fit Testing

Fit testing must occur:

• Before first use

• Annually

• When the device changes
  Many employers skip this step or lack documentation.

✅ Using the Wrong Respirator for the Hazard

Examples:

• Using filtering facepieces (N95) in environments with oxygen deficiency

• No supplied-air respirator in spray applications

• Elastomeric cartridges past their service life
  A mismatch = immediate citation.

✅ Poor Maintenance & Storage

Issues include:

• Dirty, damaged, or missing parts

• Expired cartridges

• No cleaning or inspection regimen

• Storing respirators in dirty, damp conditions
  Proper maintenance is critical to compliance.

✅ Lack of Training & Employee Understanding

Workers must know:

• Why they need the respirator

• How to don/doff it

• How to inspect it

• When to replace filters or cartridges
  Training must be documented and reviewed regularly.

Why Properly Fitted PPE Is Now Non-Negotiable

How to Stay Compliant With 1926.134 in 2025

✔ Develop and Maintain an Active Respiratory Protection Program

Include medical clearance, hazard assessment, device selection, fit-testing, training, and storage protocols.

✔ Fit Test Every Applicable Worker

Ensure you keep hard copies or digital records of each test, device, worker, and date.

✔ Match the Right Device to the Hazard

• Use supplied-air or SCBA for oxygen-deficient atmospheres

• Cartridge respirators only when correct for contaminants and properly maintained

• Disposable filtering facepieces only when acceptable by hazard assessment

✔ Inspect, Clean, and Store Properly

Create a written regimen: inspect before each use, clean after, store in sealed containers.

✔ Train and Refresh Annually

Training must cover:

• Use, limitations, and care of respirators

• Hazards that require respiratory protection

• Visual inspection steps

• Document retention and review

How Advanced Safety & Industrial Supply Helps

At Advanced Safety & Industrial Supply, we assist manufacturing, fabrication, and industrial facilities with full respiratory-protection compliance:

✅ Written program templates (customizable)
✅ On-site medical evaluations & fit-testing (qualitative and quantitative)
✅ Cartridge & filter management and alerting
✅ Cartridge-change monitoring systems
✅ Respiratory hazard assessments
✅ Training for workers and supervisors
✅ Record-keeping guidance and audit readiness