PPE test methods appendix

The pressure test measures whether a gas-tight totally-encapsulating chemical protective suit can hold a fixed positive internal pressure without leaking excessively. The appendix explains that this test evaluates the gas-tight integrity of the suit material, seams, and closures but does not test how the material resists permeation, penetration, or chemical degradation. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods and 1910.120(g).

A TECP suit is defined as a full-body garment that completely encloses the wearer and respirator by itself or in combination with tightly attached gloves and boots. The appendix gives the precise definition and clarifies that the suit covers torso, head, arms, legs and respirator, and may include tightly attached hand and foot coverings. See the definition in Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

You need a compressed air source, a test apparatus with a pressure gauge sensitive to at least 1/4 inch water gauge, vent plugs or sealing tape, soapy water and a soft brush, and a timing device. The appendix lists these required supplies and emphasizes the pressure gauge sensitivity and sealing materials needed for the test. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

The appendix requires that the pre-test expansion pressure (A) be at least 3 inches water gauge and the suit test pressure (B) be at least 2 inches water gauge unless the suit manufacturer specifies higher values. These are the minimum values and must be supplied by the suit manufacturer if different. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

A suit passes if the ending suit pressure (C) after three minutes is at least 80% of the suit test pressure (B); a pressure drop greater than 20% of B during the three-minute test is a failure. The appendix defines suit pressure drop as (B − C) and states that any drop exceeding 20 percent of B requires removal from service and repair. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

Before inflation you must visually inspect the suit (check seams, zippers, valves, connections), close all closures, seal vent valves and other openings (carefully, so you don't damage components), and create an airline connection point for inflation. The appendix describes these preparation steps and warns to avoid damaging suit components during sealing. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

You check the test apparatus by closing off the end of the tubing attached to the suit and confirming it can hold 3 inches water gauge pressure for three minutes before and after each suit test. The appendix requires this verification to ensure the test equipment is not the source of any observed leak. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

If the suit fails, inflate it to the pre-test expansion pressure (A) and brush or wipe the entire suit (including seams, closures, lens gaskets, glove-to-sleeve joints) with mild soap and water; watch for soap bubbles to identify leaks, repair them, and then retest. The appendix specifies this soap-and-water bubble inspection as the retest procedure. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

You must record a unique suit ID, brand name, purchase date, construction material, unique fit features, the actual pressures A, B, and C with observation times, whether the suit failed, and, when possible, the leak locations; also identify the test apparatus source and gauge sensitivity and retain records even if repairs are performed on site. The appendix lists these required report items for each test. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

No — the pressure test does not determine resistance to permeation, penetration, or chemical degradation; it only evaluates the gas-tight integrity against leaks. The appendix explicitly states these material-resistance characteristics are not determined by the pressure test and recommends ASTM material tests for those properties. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

The qualitative ammonia leak test is a semi-qualitative procedure that detects inward leakage of ammonia vapor into a gas-tight TECP suit by exposing the suit in an ammonia-filled test room and then measuring ammonia concentration inside the suit. This test uses real-world donning (no suit modifications) and detects leaks affecting the entire suit ensemble, not material permeation. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

The appendix specifies concentrated aqueous ammonium hydroxide (about 58% NH4OH) is used to generate the test atmosphere; the test room atmosphere should reach 1000–1200 ppm ammonia before the suit wearer begins the exercise protocol. The appendix also requires a two-minute evaporation period before measuring room concentration. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

You need high-range (0.5–10 vol%) and low-range (5–700 ppm) ammonia detector tubes with a sampling pump; a low-range or more sensitive detector is used to measure interior suit concentration, and a bromophenol-blue indicator strip (sensitive to 5–10 ppm) is placed inside the facepiece to give the wearer a visible alarm in the event of a leak. The appendix lists these required detectors and indicators. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

A stand-by person must be present outside the test room to observe the suited individual, assist with donning and doffing the suit, and measure the ammonia concentration inside the suit after the exercise protocol. The appendix requires the stand-by person and states that only the suited person (wearing positive-pressure SCBA or supplied-air respirator) should normally be inside the chamber. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods and 1910.120(g).

Only persons wearing a positive-pressure self-contained breathing apparatus (SCBA) or a positive-pressure supplied-air respirator may be inside the chamber during the ammonia test, because test-room concentrations exceed established exposure limits. The appendix points out the ammonia STEL is 35 ppm and requires positive-pressure respirators for anyone in the chamber. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods and 1910.120(g)(4).

Test participants must review the aqueous ammonia SDS, be medically screened for respirator use, and be checked for ammonia allergies; continuous monitoring of the suited individual (visual contact or communication devices) is also required. The appendix details these safety precautions to protect participants during the test. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

The intrusion coefficient is calculated by dividing the average test area (room) ammonia concentration by the concentration measured inside the suit; a larger intrusion coefficient indicates greater protection. The appendix defines the intrusion coefficient and explains its dependence on the accuracy of the monitoring methods. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

After the room reaches 1000–1200 ppm ammonia and a two-minute evaporation wait, the suited individual performs a standardized exercise protocol to flex and stress the suit; after the protocol, room concentration is re-measured, the suited person exits, and the stand-by person measures ammonia inside the suit. The appendix describes this sequence to simulate realistic wear conditions. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

Yes — the appendix allows substitution of more sensitive ammonia detectors for the low-range detector tubes to improve the sensitivity of the practice. It still lists the specified detector tube ranges as the baseline equipment. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

No — the appendix methods are non-mandatory examples of tests that may be used to evaluate compliance; other tests and challenge agents may be used instead. However, paragraph 1910.120(g) makes the use of Level A and Level B PPE mandatory in certain circumstances, so employers should use appropriate test data when selecting required protection. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods and 1910.120(g)(4)(ii).

Yes — the appendix states ASTM test methods are available and usually conducted by suit manufacturers to evaluate material resistance to permeation, penetration, and degradation, because the appendix's pressure and ammonia tests do not determine those properties. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

The appendix cautions that the suit must be completely dry inside and out before storage and that all parts be inspected and positioned correctly and secured tightly before returning the suit to service—special care should be taken to ensure exhaust valves are not blocked. See Appendix A to 1910.120 - Personal Protective Equipment Test Methods.

Multiply the test-area volume (in cubic feet) by 0.2 milliliters per cubic foot to get the approximate volume of concentrated aqueous ammonia required to generate 1000 ppm. This calculation is specified in the test method in 1910.120AppA.

Measure the pre-calculated volume from the supply of concentrated aqueous ammonia into a closed plastic container, and place that container together with several high-range ammonia detector tubes and the sampling pump into a clean test pan near the test-area entry door so the suited individual can easily access them. The appendix directs these exact preparation and placement steps in 1910.120AppA.

No — do not plug off any venting valves during the test. The procedure explicitly warns against plugging venting valves in 1910.120AppA.

During the test the chamber should be an enclosed room (closet, bathroom, or test booth) equipped with an exhaust fan but the fan must not be running because exhausting air would dilute the ammonia challenge; after the test you must turn on the ventilating fan and vent it to the outside to remove the ammonia gas. These requirements are stated in 1910.120AppA.

Open a pre-sealed ammonia indicator strip in a non-contaminated atmosphere and fasten one end to the inside of the suit face shield lens where the wearer can see it; moisten the strip with distilled water and avoid touching the detector area (use a small piece of masking tape to attach). If attachment inside the shield is impractical, the appendix allows attaching the strip to the outside of the respirator face piece lens. See 1910.120AppA for these steps.

Don the respiratory protective device normally used with the suit first, and then don the gas-tight totally encapsulating chemical protective (TECP) suit; after donning, check that all openings intended to be sealed (zippers, gloves, etc.) are fully sealed. The donning order and seal check are specified in 1910.120AppA.

You must generate a chamber concentration of 1000 ppm ammonia or greater before starting the exercises, and verify that concentration with a high-range colorimetric detector tube (or equivalent high-range monitor). The requirement to reach and confirm 1000 ppm is found in 1910.120AppA.

The test uses a four-minute exercise sequence: (1) raising the arms above the head with at least 15 raises in one minute; (2) walking in place for one minute with at least 15 raises of each leg; (3) touching the toes with at least 10 full arm motions from overhead to toe touching in one minute; and (4) knee bends with at least 10 complete standing-squatting motions in one minute. This protocol is described in 1910.120AppA.

Stop the test immediately and follow the procedures for stopping and measuring interior concentrations (exit the test area, then use the opening created by the zipper or other penetration to sample the suit interior with a low-range length-of-stain detector tube or other ammonia monitor). These steps are set out in 1910.120AppA.

Sample the suit interior air far enough from the enclosed test area and, when practical, use the opening created by the suit zipper or an appropriate suit penetration to draw the sample; this prevents false readings from chamber leakage. Use a low-range length-of-stain detector tube or another suitable ammonia monitor for the interior sample as described in 1910.120AppA.

Any detectable ammonia of five ppm or greater measured by the length-of-stain detector tube in the suit interior indicates the suit has failed; if you use other detectors with a lower detection limit you may adopt a lower pass/fail threshold but you must specify that detection limit as your pass/fail criterion. The pass/fail criteria are stated in 1910.120AppA.

The test method is designed to measure an intrusion coefficient; an intrusion coefficient of approximately 200 or more indicates the suit is suitable for emergency response and field use. The method and suitability threshold are described in 1910.120AppA. For reporting, you must record the two test-area concentrations, their average, the interior suit concentration, and the calculated intrusion coefficient as required in the appendix (see the reporting section).

If the suit fails, first check for leaks by performing the pressure test defined earlier in the test methods (test A), repair any leaks found, and then retest the suit following the full test procedure in section 6.0. The retest procedure and leak-check instruction are given in 1910.120AppA.

You must record: a unique identification number and suit details (brand, purchase date, material, special features); a general description of the test room; brand and purchase date of ammonia detector strips and color change data; brand, sampling range, and expiration date of length-of-stain ammonia detector tubes plus pump model (or identify any other type of ammonia detector and its minimum detection limit); actual test results showing the two test-area concentrations, their average, the interior suit concentration, and the calculated intrusion coefficient; and an evaluation labeled “suit passed” or “suit failed” with the test date. See the full reporting list in 1910.120AppA.

Visually inspect all parts of the suit to ensure everything is correctly positioned and secured, take special care to examine each exhaust valve to ensure it is not blocked, and make sure the inside and outside of the suit are completely dry before storage. These cautionary steps are included in 1910.120AppA.

Yes — a small mixing fan may be used near the evaporation pan to increase the evaporation rate of the ammonia solution during the two-minute wait. The appendix specifically allows using a small mixing fan in 1910.120AppA.

Wait two minutes after pouring the pre-measured concentrated aqueous ammonia into the empty plastic test pan to allow for adequate volatilization, then measure the chamber concentration using a high-range colorimetric detector tube. This timing and measurement step are in 1910.120AppA.

Record the brand name and purchase date of ammonia detector strips and color change data, and record the brand name, sampling range, and expiration date of the length-of-stain ammonia detector tubes plus the brand and model of the sampling pump; if you use a different type of ammonia detector, identify it and record its minimum detection limit for ammonia. These documentation requirements are listed in 1910.120AppA.