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Industry Insights

Clinic vs. Online Respirator Medical Evaluations: Cost, Time & Compliance Comparison

Dr. Nader Mikhail

12 min read

Updated: October 10, 2025

Clinic vs online respirator medical evaluation comparison

Choosing how to conduct OSHA-required respirator medical evaluations is one of the most impactful decisions for workplace safety programs. The choice affects your budget, employee productivity, administrative workload, and compliance effectiveness.

For decades, the only option was sending employees to occupational health clinics for in-person evaluations. But the rise of online medical evaluation platforms has transformed respiratory protection compliance, offering significant advantages in cost, speed, and administrative efficiency.

Understanding Both Methods

Traditional Clinic-Based Evaluations

Process:

  • 1. Employee schedules appointment at occupational health clinic
  • 2. Employee travels to clinic during work hours
  • 3. Employee completes OSHA Appendix C questionnaire on-site
  • 4. Clinic staff or physician reviews questionnaire
  • 5. PLHCP provides medical clearance decision
  • 6. Clinic mails or faxes certificate to employer
  • 7. Employer manually files certificate and tracks expiration

Timeline: 1-2 weeks from scheduling to certificate delivery

Typical Cost: $50-$150 per evaluation (clinic fee only)

PLHCP Review: In-person or telehealth consultation with clinic physician

Online Medical Evaluation Platforms

Process:

  • 1. Employer purchases evaluation credits and receives access codes
  • 2. Employee enters access code and completes OSHA Appendix C questionnaire online
  • 3. Platform automatically evaluates responses using medical algorithms
  • 4. Clear responses (98% of cases) receive instant PLHCP-approved clearance
  • 5. Flagged responses route to Medical Review Officer for consultation
  • 6. Digital certificate delivered instantly to employee and employer dashboard
  • 7. Platform automatically tracks expiration and sends renewal reminders

Timeline: 10 minutes from start to certificate download (for clear responses)

Typical Cost: $17-$22 per evaluation (volume-based pricing)

PLHCP Review: Physician-developed algorithms for clear responses; direct PLHCP review for flagged cases

Compliance Equivalence: Are Online Evaluations OSHA-Compliant?

Short answer: Yes, when properly implemented.

OSHA does NOT require in-person examinations for routine evaluations, physical exams unless the PLHCP determines they are necessary, or clinic visits or face-to-face appointments. OSHA explicitly allows for electronic questionnaires and remote PLHCP review, as long as the process meets all regulatory requirements.

Cost Comparison: True Total Cost of Ownership

FactorClinicOnlineSavings
Evaluation Fee$50-$150$17-$22$28-$133
Employee Time$70-$140$6$64-$134
Travel$20$0$20
Administration$26$0$26
Total per Employee$166-$336$23-$28$138-$308
Real-World Example

A mid-sized manufacturing company with 120 respirator users switched from clinic evaluations ($110 avg.) to an online platform ($18 avg.):

  • • Previous annual cost: $38,400 (clinic fees + employee time + administration)
  • • New annual cost: $3,360 (platform fees + minimal employee time)
  • • Annual savings: $35,040 (91% reduction)
  • • 3-year savings: $105,120

Learn more about the hidden costs of traditional respirator testing.

Time Comparison: Productivity Impact

Beyond cost, the time required for respirator medical evaluations significantly impacts workforce productivity.

ActivityClinicOnline
Scheduling Time30-60 minutes + 1-3 weeks wait5 minutes for entire batch
Employee Time Away2-4 hours10 minutes
Results Delivery1-7 daysInstant
Total Timeline2-3 weeks10 minutes
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