Respiratory protection is consistently among the top cited OSHA standards year after year. OSHA 29 CFR 1910.134 requires employers to establish and maintain a respiratory protection program with regular inspection, cleaning, maintenance, and storage procedures for all respirators. Whether employees use filtering facepieces, half-face or full-face air-purifying respirators, or self-contained breathing apparatus (SCBA), proper inspection ensures the equipment will protect workers from harmful airborne contaminants including dusts, fumes, mists, gases, and vapors. This guide covers all inspection requirements with a free downloadable checklist.
Free Respiratory Protection Inspection Checklist
Download our Word document checklist covering pre-use inspection, facepiece condition, cartridge/filter status, SCBA inspection, and storage per OSHA 1910.134.
Download Checklist (.docx)Regulatory Framework
OSHA 29 CFR 1910.134 — Respiratory Protection
- 1910.134(c): Employer must establish and implement a written respiratory protection program with worksite-specific procedures, administered by a qualified program administrator.
- 1910.134(d): Respirators must be NIOSH-certified and selected based on the hazard, assigned protection factors (APFs), and maximum use concentration (MUC).
- 1910.134(e): Medical evaluations required before fit testing and respirator use. PLHCP must determine employee ability to use a respirator.
- 1910.134(f): Fit testing required before initial use, when different facepiece used, and at least annually thereafter using Appendix A procedures.
- 1910.134(h): Maintenance and care requirements including inspection, cleaning/disinfecting, repair, and storage.
- 1910.134(k): Training required before use and annually, covering why the respirator is necessary, limitations, proper use, inspection, maintenance, storage, and medical signs/symptoms.
Top OSHA violation: Respiratory protection (1910.134) is consistently one of the most frequently cited OSHA standards across all industries. Common violations include lack of a written program, failure to conduct fit testing, inadequate training, and failure to perform required inspections and maintenance.
Part 1: Pre-Use Respirator Inspection
| Inspection Item | What to Check |
|---|---|
| Facepiece condition | No cracks, tears, holes, or distortion in the facepiece. Elastomeric material pliable, not hardened or deteriorated. Lens (full-face) not cracked, scratched excessively, or loose. Sealing surfaces clean and undamaged. |
| Head straps | Straps not stretched, torn, or frayed. Buckles and fasteners intact and functional. Straps provide proper tension for adequate seal. No modifications or field repairs to strap system. |
| Inhalation and exhalation valves | Valves present, seated properly, and not distorted or stuck. Valve covers in place and secure. Exhalation valve functions freely (opens on exhalation, seats on inhalation). No tears, warping, or buildup on valve surfaces. |
| Cartridges/canisters/filters | Correct type for the identified hazard (organic vapor, acid gas, P100, combination, etc.). Not expired past manufacturer shelf life. End-of-service-life indicator (if equipped) not activated. Connections secure and gaskets intact. Filters not damaged, wet, or contaminated. |
| User seal check | Positive and negative pressure seal checks performed each time respirator is donned per 1910.134(g)(1)(iii) and Appendix B-1. No facial hair between the sealing surface and face. No conditions interfering with seal (glasses temples, bandanas, etc.). |
Part 2: SCBA & Emergency Respirator Inspection
| Inspection Item | What to Check |
|---|---|
| Monthly inspection (required) | Emergency-use respirators including SCBAs inspected at least monthly per 1910.134(h)(3)(ii). Written inspection record required with date, inspector name, findings, corrective actions, and equipment serial number. |
| Cylinder pressure | Air or oxygen cylinder pressure at least 90% of manufacturer recommended pressure level. Cylinder within hydrostatic test date per DOT requirements. Cylinder not dented, corroded, or damaged. Valve operates smoothly. |
| Regulator and alarm | Regulator operates properly with no air leaks. Low-air alarm (PASS alarm) functional and activates at correct pressure. Bypass valve operational. Breathing resistance within normal parameters. |
| Harness and frame | Backpack frame not cracked or bent. Harness straps intact with functional buckles. Waist and shoulder straps adjustable. No damage to carrying case or storage cabinet. Quick-connect fittings operational. |
| Facepiece and hose | SCBA facepiece inspected per Part 1 criteria. Breathing hose not cracked, kinked, or deteriorated. All connections tight and sealed. Heads-up display (HUD) functional if equipped. |
Part 3: Cleaning, Storage & Program Compliance
| Inspection Item | What to Check |
|---|---|
| Cleaning and disinfecting | Respirators cleaned and disinfected per Appendix B-2 procedures or manufacturer equivalent. Single-user respirators cleaned as often as necessary. Shared respirators cleaned after each use. Emergency respirators cleaned after each use. |
| Storage conditions | Respirators stored to protect from damage, contamination, dust, sunlight, extreme temperatures, excessive moisture, and damaging chemicals per 1910.134(h)(2). Emergency respirators stored accessible and clearly marked. Not stored in sealed plastic bags when wet. |
| Fit testing records | Current annual fit test on file for each respirator user. Records include employee name, respirator type/model/size, test method (QLFT or QNFT), and pass/fail results. Records retained until next fit test per 1910.134(m)(2). |
| Medical evaluation records | Medical evaluation completed before fit testing and respirator use. PLHCP clearance on file. Records retained per 29 CFR 1910.1020 medical record requirements (duration of employment plus 30 years). |
| Training documentation | Initial and annual training completed and documented for all respirator users. Training covers: why respirator is necessary, capabilities and limitations, proper donning and use, inspection and maintenance, medical symptoms, and emergency procedures. |
| Written program | Current written respiratory protection program on file and available to employees per 1910.134(c). Program includes worksite-specific procedures, hazard evaluation, respirator selection, fit testing, medical evaluation, training, and program evaluation. |
Respirator inspection frequency summary: Before each use: user inspection and seal check for all routine-use respirators. After each use: cleaning and disinfection for shared respirators. Monthly: written inspection of all emergency-use respirators (SCBAs, escape respirators). Annually: fit testing for each employee. Program evaluation should be conducted regularly to ensure ongoing effectiveness per 1910.134(l).
Remove from Service Immediately
Remove any respirator from service when: facepiece cracked, torn, or excessively worn; valves missing, damaged, or not sealing; head straps stretched or no longer provide adequate tension; cartridges/canisters expired, contaminated, or wrong type; SCBA cylinder below 90% of rated pressure; SCBA low-air alarm non-functional; any component damaged or defective; respirator fails fit test; respirator cannot be properly cleaned or disinfected.
Download the Free Checklist
Get our respiratory protection inspection checklist in Word format. Covers all OSHA 1910.134 requirements.
Download Checklist (.docx)Go digital with Ecesis. Replace paper respirator inspection logs with Ecesis inspection software. Track fit testing schedules and medical evaluations. Manage cartridge change-out schedules. Document SCBA monthly inspections with serial number tracking. Maintain complete compliance records for OSHA audits. Request a free demo.
Ecesis EHS Software
Inspections
Respirator-specific inspection checklists with serial number tracking and deficiency management.
Safety Inspections
PPE compliance inspections covering respiratory protection across all departments.
Preventive Maintenance
Schedule SCBA monthly inspections, cylinder hydrostatic testing, and annual servicing.
Compliance Calendar
Track annual fit testing, medical evaluations, and training due dates automatically.
Task Management
Assign corrective actions for deficient respirators and track replacements to completion.
Training
Track respirator training, fit testing certifications, and medical evaluation due dates.
