Respiratory protection in the workplace safeguards workers from harmful gases, preventing acute health issues, chronic illnesses, and fatalities while ensuring compliance with safety regulations and fostering a healthier, more productive workforce.
In January 2025, OSHA fined a Pennsylvania soap manufacturer $161,310 for exposing a dozen workers to hazardous gases (more on that below), underscoring the importance of respiratory protection in industrial settings.
Hazardous gases pose significant risks to worker health, ranging from respiratory irritation to long-term chronic conditions, and in some cases, even fatalities.
All this means that you must prioritize safety measures to mitigate these risks and ensure compliance with OSHA standards.
Here, we’ll outline eight key tips for protecting workers from hazardous gases, drawing on OSHA guidelines and best practices in respiratory protection.
Related Article: Key Benefits of a Workplace Respiratory Protection Program.
Related Article: Industrial Gas Manufacturing Plant Faces $201K in Fines Following Diborane Explosion, Injuries.
OSHA Cites Pennsylvania Soap and Detergent Manufacturer After Hazardous Gas Release
In a recent report, OSHA cited a Chambersburg, Pennsylvania, soap and detergent manufacturer, after 12 workers were affected by a nitrogen dioxide exposure, leaving two workers hospitalized.
The company was found to have inadequate respiratory protection measures, insufficient emergency response protocols, and a lack of proper training for employees. OSHA emphasized the importance of implementing engineering controls, providing appropriate personal protective equipment (PPE), and ensuring workers are trained to handle hazardous materials safely.
The company faces $161,310 in proposed penalties for one repeat violation, as well as nine serious and two other-than-serious violations.
Since 2022, OSHA has cited this manufacturer for four serious violations for failures to protect employees at its Emerson, Georgia, facility from hazardous chemicals.
They have 15 business days from receipt of its citations and penalties to comply, request an informal conference with OSHA’s area director, or contest the findings before the independent Occupational Safety and Health Review Commission.
Key Tips for Protecting Workers from Hazardous Gases
1. Conduct Thorough Risk Assessments
The first step in protecting workers from hazardous gases is identifying potential risks. You must conduct comprehensive risk assessments to determine the types of gases present, their concentrations, and the likelihood of exposure.
This process involves air monitoring, maintaining an up-to-date inventory of all chemicals used or produced in the facility, and familiarizing workers with OSHA’s Permissible Exposure Limits (PELs).
By understanding the specific hazards in your workplace, you can implement targeted controls to minimize risks.
2. Implement Engineering Controls
Engineering controls are the most effective way to reduce exposure to hazardous gases. These measures involve modifying equipment or processes to eliminate or minimize the release of harmful substances.
Examples include:
– Installing local exhaust ventilation (LEV) systems to capture and remove gases at their source,
– Isolating processes that generate hazardous gases in enclosed systems to prevent their release into the workplace, and
– Using automated systems to handle hazardous materials, reducing the need for worker involvement in high-risk tasks.
Engineering controls should be prioritized because they address hazards at the source, providing long-term protection.
3. Provide Appropriate Respiratory Protection
When engineering controls cannot fully eliminate exposure, respiratory protection becomes essential. As an employer, you’re required to provide your workers with the right type of respirators based on the specific hazards present.
Key considerations include:
– Choosing respirators that are approved by the National Institute for Occupational Safety and Health (NIOSH) and appropriate for the gases in question,
– Conducting fit-tests annually or whenever there are changes in the worker’s facial structure, and
– Training workers on how to use, maintain, and inspect their respirators.
Respiratory protection programs must also include medical evaluations to ensure workers are physically capable of wearing respirators.
Need to schedule respirator fit-testings for your team? Get started, right here: Schedule Respirator Fit-testing
4. Establish Clear Emergency Procedures
Despite preventive measures, accidents can still occur. Employers must have robust emergency procedures in place to respond to hazardous gas releases.
Key components include:
– Conducting regular drills to ensure workers know what to do in an emergency.
– Providing readily accessible emergency equipment, such as eyewash stations, safety showers, and spill containment kits, and
– Implementing reliable communication systems to alert workers of emergencies and coordinate responses.
Having a well-prepared emergency plan can save lives and minimize injuries during critical incidents.
5. Train Workers on Hazard Awareness and Safe Practices
Worker training is a cornerstone of any effective safety program. Employees must understand the risks associated with hazardous gases and how to protect themselves.
Training should cover the following:
– Teaching workers to recognize the signs of gas leaks or exposure, such as unusual odors, dizziness, or respiratory discomfort,
– Emphasizing the importance of following established procedures, such as wearing PPE, using ventilation systems, and reporting hazards, and
– Ensuring workers know how to respond in the event of a gas release, including evacuation procedures and first aid measures.
Regular refresher training helps reinforce these concepts and keeps safety top of mind.
6. Monitor and Maintain Equipment
Proper maintenance of equipment is critical to preventing hazardous gas exposures.
Employers should:
– Check ventilation systems regularly to ensure they are functioning correctly and efficiently,
– Calibrate gas detection equipment according to manufacturer recommendations to ensure accurate readings, and
– Follow the manufacturer’s guidelines for replacing respirator filters and cartridges to maintain their effectiveness.
Neglecting equipment maintenance can lead to failures that compromise worker safety.
7. Foster a Culture of Safety
A strong safety culture is essential for protecting workers from hazardous gases.
To help promote this culture, make sure you demonstrate a commitment to safety by prioritizing it in decision-making and daily operations. You should also ensure your workers feel comfortable reporting hazards or near-misses without fear of retaliation.
Finally, make sure you acknowledge and reward workers who consistently follow safety protocols.
When safety becomes a shared value, workers are more likely to adhere to protective measures and look out for one another.
8. Stay Informed and Compliant
OSHA regulations and industry standards are continually evolving. As such, make sure you stay informed about changes and ensure your safety programs remain compliant.
This includes:
– Conducting regular audits of your safety program to identify gaps and areas for improvement,
– Monitoring OSHA announcements and updates to stay current on new requirements or guidance, and
– Participating in industry associations and forums to learn about emerging trends and best practices in respiratory protection.
Proactive compliance not only protects workers but also helps avoid costly fines and penalties.
Key Takeaways
Protecting workers from hazardous gases requires a multifaceted approach that combines risk assessment, engineering controls, respiratory protection, emergency preparedness, training, equipment maintenance, and a strong safety culture.
The recent OSHA citation of a soap manufacturer serves as a stark reminder of the consequences of neglecting these responsibilities. By implementing the tips outlined in this article, employers can create a safer work environment, safeguard worker health, and ensure compliance with regulatory standards.
Remember, safety isn’t just your legal obligation, it’s a moral imperative!
Stay In Compliance With Worksite Medical
In most cases, OSHA requires medical surveillance testing, and at no cost to employees.
Worksite Medical makes that program easier with mobile medical testing.
We conduct silica exam physicals, on-site respirator fit tests (including N95 masks), audiometric exams, as well as pulmonary function tests and heavy metal lab work, and much more, right on your job site. We also keep accurate, easy-to-access medical records for your convenience. You’ll keep your employees at work, and stay ahead of OSHA inspections.
With Worksite Medical, a mobile medical testing unit — we can bring all the resources of a lab to you. Our certified lab technicians can perform both qualitative and quantitative respirator tests to ensure a perfect fit.
Protect your team and your workplace now with Worksite Medical. Not sure what you need? Try our medical testing wizard here.
Give us a call at 1-844-622-8633, or complete the form below to schedule an on-site visit or to get your free quote.
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