Respirator Safety in Canada: Rules, CSA Z94.4 & Fit Testing

Respirators are personal protective equipment that keep hazardous particles, gases and vapours out of workers' lungs, and in Canada their use at work is regulated in every jurisdiction. For federally regulated workplaces within the scope of the Canada Occupational Health and Safety Regulations, respirator requirements are in Part XII, section 12.13 1; each province and territory has its own respirator provisions; and most of them point to one document: CSA Standard Z94.4, Selection, Use, and Care of Respirators 3,23. This guide covers the types of respirators, the hazards they protect against, the law in all 14 jurisdictions, fit testing, and how respirator training and certification work.

What are respirators?

Respirators are personal protective equipment (PPE) designed to protect the wearer from inhaling harmful substances, such as hazardous particles, gases, vapours, or airborne contaminants. They create a barrier between the respiratory system (lungs and airways) and the surrounding environment to reduce the risk of respiratory exposure to hazardous materials 4.

What are the main types of respirators, and how do they work?

There are two main types of respirators: air-purifying respirators (APRs) and atmosphere-supplying respirators 4.

Air-purifying respirators (APRs)

Air-purifying respirators use filters or cartridges to remove contaminants from the air before they are breathed in. Two common filtering categories are:

• Particulate respirators: filter dust, fumes and mists. They are common in construction, agriculture and healthcare.
• Gas and vapour respirators: use chemical cartridges to remove specific gases and vapours. They are common in manufacturing and chemical processing.

Atmosphere-supplying respirators

Atmosphere-supplying respirators provide clean breathing air from a source other than the surrounding air, such as a compressed air tank or air compressor. There are two types:

• Self-contained breathing apparatus (SCBA): worn on the back with its own clean-air supply. SCBAs are used by firefighters and in the oil and gas industry.
• Supplied-air (airline) respirators: connected by a hose to a separate clean-air source. They are used in spray painting and abrasive blasting.

It is important for employers to provide the appropriate type of respirator for the specific hazards present in the workplace and to ensure that workers receive proper training on the use of respirators.

Air-purifying respirators do not supply oxygen and cannot be used in oxygen-deficient atmospheres. Selection depends on the contaminant, concentration, oxygen level and the work to be done. 4

What are the main respiratory hazards?

There are several hazards associated with respirator safety, including exposure to harmful airborne particles, gases, and vapours. Inhaling these substances can cause a variety of health problems, including respiratory irritation, lung damage, and even death in severe cases.

Additionally, improper use or maintenance of respirators can lead to discomfort, poor fit, and leakage, which can compromise the effectiveness of the equipment and increase the risk of exposure.

It is essential to identify and assess the specific hazards present in the workplace and select appropriate respirators and training to mitigate those hazards.

Here are some common hazards and industries where they may be encountered:

• Particulate matter: Refers to tiny airborne particles such as dust, dirt, and soot. Exposure to particulate matter can cause respiratory irritation, coughing, and shortness of breath. Industries that may encounter particulate matter include construction, mining, and agriculture. 26,6
• Chemical vapours: Refers to the gaseous form of substances that are normally liquid or solid that can cause harm when inhaled. Inhaled chemicals can harm the lungs and, after entering the bloodstream, other organs. Industries that may encounter chemical vapours include manufacturing, automotive repair, and laboratories. 27
• Biological agents: Refers to bacteria, viruses, and other microorganisms that can cause illness when inhaled. These agents can be found in healthcare facilities, laboratories, and other industries where workers may come into contact with infectious materials. 25
• Asbestos: Refers to a naturally occurring mineral fibre that was commonly used in building materials until it was found to cause serious health problems, including lung cancer and mesothelioma. Asbestos can be found in older buildings, particularly those built before 1990 5.
• Welding fumes: Welding produces fine solid particles as well as gases. These fumes can cause respiratory irritation, and long-term exposure can lead to serious health problems such as lung cancer. Welding fumes are commonly encountered in the manufacturing and construction industries. 24

What are the main health risks?

Respiratory hazards can have severe health effects on workers and can lead to serious medical conditions. Some of the health risks associated with poor respiratory safety include:

• Respiratory diseases: depending on the substance, chronic exposure can lead to COPD, asthma and lung cancer 6,24.
• Irritation and discomfort: eye, nose and throat irritation, coughing and shortness of breath. 24,6
• Oxygen deficiency: in confined spaces, the atmosphere can fail to support life without supplied air 4.
• Asphyxiation: toxic gases such as carbon monoxide can be fatal at high concentrations 24.

What is the federal legislation for respirators?

Canada Occupational Health and Safety Regulations

The Canada Occupational Health and Safety Regulations (COHSR, SOR/86-304) are federal regulations that govern the occupational health and safety of workers in federally regulated workplaces covered by these regulations. Respiratory protection is covered in Part XII, Protection Equipment and Other Preventive Measures, under section 12.13, Respiratory Protection, which sets out specific requirements for the selection, use, and care of respirators 1.

Some federal activities fall under sector-specific regulations: section 1.4 excludes employees working on trains or aircraft while in operation, on ships, and in specified oil and gas activities, among others. Check which regulations cover your work. 1

Under section 12.13 of COHSR, employers are required to provide respiratory protective equipment to every person granted access to a workplace where there is a risk of injury or disease from breathing hazardous air, such as an oxygen-deficient atmosphere. Section 12.13 sets out the equipment requirements, while section 12.2 requires instruction from a qualified person for every person who uses protection equipment, plus training for employees in its use, operation and maintenance 1.

Canada Labour Code

The Canada Labour Code (CLC) is federal legislation that regulates employment and labour relations in federally regulated industries. Part II of the CLC sets out the occupational health and safety standards that employers must follow to ensure the safety and well-being of their workers.

Under Part II of the CLC, employers are required to identify workplace hazards and take measures to eliminate or control them. Every employer must provide prescribed safety materials, equipment, devices and clothing, including respirators (s. 125(1)(l)), and must provide each employee with the information, instruction, training and supervision necessary to ensure their health and safety at work (s. 125(1)(q)) 8.

The detailed equipment requirements for respirators are set out in COHSR section 12.13, which is made under Part II of the CLC. For oxygen deficiency or airborne hazardous substances other than CBRN agents, respiratory protective equipment must meet the following requirements 1:

• respiratory protective equipment for oxygen-deficient atmospheres and air-supplied equipment must be listed in the U.S. NIOSH Certified Equipment List;
• non-air-supplied respirators may be listed either in the NIOSH Certified Equipment List or in the CSA Group Product Listing, and CSA-listed filtering respirators must also meet CSA Z94.4.1;
• it must meet CSA Standard Z94.4, Selection, Use, and Care of Respirators (s. 12.13(1)(b) and (2)(d));
• it must be used and cared for in accordance with CSA Z94.4 (s. 12.13(4)); equipment with a potentially unsafe defect must be taken out of service (s. 12.19);
• supplied-air systems must meet CSA Z180.1, Compressed Breathing Air and Systems (s. 12.13.1).

What is the provincial and territorial legislation for respirators?

Every province and territory has its own legislation on respirator use, and most of them reference the same standard, CSA Z94.4, directly or indirectly. The table below summarizes the core respirator requirement in each jurisdiction. Employers should always check the specific regulation that applies to their workplace.

Respirator requirements by jurisdiction

Which CSA standard applies to respirators in Canada?

CSA Z94.4 is the principal Canadian respiratory-protection standard and is referenced directly or indirectly across Canadian jurisdictions, although the way it is incorporated and the edition cited vary by jurisdiction. CSA Group lists CAN/CSA-Z94.4-18 (R2023), also referenced by CCOHS, but several jurisdictions name an earlier edition in their legislation. 2 For example, Manitoba and Quebec name Z94.4-11, New Brunswick names Z94.4-11 (R2016), and Alberta and Yukon name Z94.4-02. Always check which edition your jurisdiction’s regulation cites. 3,13,16,17,10,21

What is a respiratory protection program?

A respiratory protection program is the employer’s written plan for selecting, using and caring for respirators at a workplace. CCOHS lists components such as hazard identification and control, exposure assessment, respirator selection, fit testing, training, inspection and record keeping, cleaning, maintenance and storage, health surveillance, written procedures and program evaluation. 4 Some regulations name it expressly, for example Quebec (s. 45.1) and Newfoundland and Labrador (s. 83). 16,20

What training do workers who wear respirators need?

Respirator protection training is a crucial aspect of ensuring worker safety when using respirators. Proper training can help workers select the appropriate respirator, use it correctly, and maintain it properly.

Who is responsible for training workers on respirators?

Employers are responsible for providing respirator protection training to their workers, as well as ensuring that the appropriate PPE is available and properly maintained. Workers, in turn, are responsible for attending respirator protection training, properly using the equipment provided, and reporting any issues or concerns to their employer. 8,14,13

Who must be trained to use a respirator?

Respirator protection training is necessary for workers in various industries where respiratory hazards are present. Here are some examples of industries that may require respirator protection training:

• Construction: Construction workers often encounter respiratory hazards such as dust, fumes, and hazardous chemicals. They may be involved in activities like demolition, concrete cutting, and painting, which generate airborne particles and toxins that can be harmful when inhaled.
• Manufacturing: The manufacturing industry involves various processes that emit fumes, vapours, and chemicals. Workers in manufacturing plants, especially those involved in chemical production, metalworking, or printing, may face respiratory hazards and require proper training to protect themselves from harmful airborne contaminants.
• Healthcare: In healthcare settings, workers may encounter biological hazards, infectious agents, and airborne diseases. Respirator protection training is crucial for healthcare professionals who work in hospitals, laboratories, or isolation units, as they may come into contact with patients or specimens carrying contagious respiratory illnesses.
• Agriculture: Agricultural workers, such as farmers, pesticide applicators, and livestock handlers, may be exposed to respiratory hazards such as dust, pesticides, and organic materials. Respirator protection training helps them mitigate the risks associated with handling and working around these substances.
• Mining: Miners work in environments where they may encounter toxic gases, dust, and particulate matter. Proper respiratory protection training is essential for miners to prevent respiratory diseases caused by prolonged exposure to hazardous substances found in mines.
• Automotive and repair: Workers in automotive repair shops may be exposed to chemical fumes, exhaust emissions, and particles from sanding or grinding activities. Respirator protection training is important to safeguard their respiratory health while working on vehicles or handling chemicals.
• Emergency response: First responders, firefighters, and hazardous material (HAZMAT) teams often face respiratory hazards during emergency situations. They need proper training to select and use the appropriate respiratory protection equipment to ensure their safety when dealing with hazardous environments or substances.

Remember, each industry may have specific respiratory hazards unique to their operations, and tailored respirator protection training is necessary to address those hazards effectively.

These are examples of exposure situations, not a rule that every worker in each industry needs the same respirator. The employer’s hazard assessment and applicable program determine the protection and training needed. 4,25

Which part of the training can be done online?

The theory component of respirator training can be completed online. Our Respirators course covers the theory in about 45 minutes across two modules: what respirators are, the types and their limits, the respiratory hazards you may face, and how a respiratory protection program works, including selection, cleaning, inspection, storage and the evaluations required before use. The course includes two online tests.

Where respirator use is required, an online certificate is not the whole picture. Employers must also ensure that any applicable workplace-specific instruction, competency requirements and fit testing are completed. If your job requires a tight-fitting respirator, you will need a fit test conducted in person before first use and repeated on your jurisdiction's schedule. The course prepares you for what the fit test involves; your employer arranges the test itself. Some regulations also expressly require practical experience in an uncontaminated environment. 11,7,22

What must workers be taught about respirators?

Respirator protection training should include the following elements:

• The hazards that respirators protect against.
• The types and limitations of respirators.
• How to select, use, and maintain respirators.
• The purpose of fit testing, when it is required, and what to expect during a fit test.
• How to inspect and maintain respirators.
• Cleaning and storage of respirators, and the conditions that can interfere with the seal, such as facial hair.
• How to recognize and respond to respiratory problems.

These topics need to be applied to the equipment and hazards at the workplace. 1,14,13,4,25

When does the law require respirator retraining?

Training renewal and fit testing run on separate schedules.

There is no single Canada-wide expiry period for respirator training certificates. The eSafetyFirst Respirators certificate carries a printed expiry of three years from completion; that is our program’s practice, separate from the employer’s duty to keep workers trained and competent.

Some uses have mandatory refresher intervals. Alberta requires at least annual training for health-care workers who may be exposed to airborne biohazardous material. Saskatchewan, the Northwest Territories and Nunavut require semi-annual refresher training for workers who may use emergency-only respirators. CSA Z94.4 also covers initial and periodic training; check the edition incorporated by your jurisdiction and your workplace program. 2 Retraining may also be needed sooner when hazards, equipment, procedures or a worker’s ability to use the respirator change. 10,11,7,22

What is respirator fit testing, and how often is it required?

A fit test checks that a tight-fitting respirator seals effectively against the wearer’s face, using either a fit-testing agent (qualitative test) or a machine that measures the seal (quantitative test). 23 Fit testing is a separate requirement from training. CCOHS recommends repeating fit testing every two years, while British Columbia requires it before first use and at least once a year. A fit test is also needed sooner after changes that can affect the seal, such as changes to face shape, weight, dental work or respirator make, model or size. Follow the interval and triggers required in your jurisdiction. 23,9

Key takeaways

Respirator use is regulated in every Canadian jurisdiction, from COHSR section 12.13 for federally regulated workplaces covered by those regulations to the regulations of each province and territory, and CSA Z94.4 is the principal standard behind how respirators are selected, used and cared for. For workers who wear a respirator, that comes down to three things: the right respirator for the hazard, a fit test for tight-fitting models, and training before first use. When correctly selected, fitted, used and maintained within its limitations, a respirator can provide the intended level of protection.