How Much Does a Respirator Medical Evaluation Cost?
Complete 2025 pricing guide with cost comparisons, hidden fees, and savings strategies
January 15, 2025
If your company requires employees to wear respirators, you're legally required to provide OSHA-compliant medical evaluations before fit testing or respirator use. But the cost varies dramatically depending on where and how you get these evaluations completed.
In this comprehensive 2025 pricing guide, we'll break down the real cost of respirator medical evaluations, including hidden fees most companies overlook, and show you how to save thousands annually while maintaining full OSHA compliance. For a complete solution that tracks medical evaluations, fit tests, and training records automatically, explore our respirator program management software.
Table of Contents
- National Pricing Survey Results
- Cost Breakdown by Provider Type
- Hidden Costs You're Probably Missing
- Volume Pricing and Discounts
- ROI Calculator for Your Company Size
- How to Reduce Costs Without Compromising Compliance
- Frequently Asked Questions
2025 National Pricing Survey Results
We surveyed 200+ occupational health providers across the United States to establish baseline pricing for OSHA-compliant respirator medical evaluations. Here's what we found:
| Provider Type | Price Range | Average Cost | Time Required |
|---|---|---|---|
| Online Evaluation (RespiratorTest.com) | $17-22 | $19 | 15 minutes |
| Urgent Care Clinic | $75-125 | $95 | 2-3 hours |
| Occupational Health Clinic | $100-150 | $125 | 2-4 hours |
| Mobile Clinic (On-site) | $125-200 | $160 | 1-2 hours |
| Hospital-Based Clinic | $150-300 | $225 | 3-5 hours |
Key Finding: Online evaluations cost 85-90% less than traditional clinic visits while providing identical OSHA compliance. The massive price difference is due to operational efficiency, not quality of care. For comprehensive industry cost trends and compliance data, see our 2025 Respirator Compliance Report.
Detailed Cost Breakdown by Provider Type
Online Evaluation: $17-22
Online respirator medical evaluations offer the lowest cost while maintaining full OSHA 1910.134 compliance:
What's Included: OSHA Appendix C questionnaire, licensed PLHCP review (MD/DO), digital certificate, 30-year digital record retention, instant results (98%)
Time Required: 10-15 minutes to complete questionnaire
Volume Pricing: $17/evaluation for 100+ certificates
Additional Fees: None (no travel, no co-pays, no hidden charges)
Occupational Health Clinic: $100-150
Traditional occupational health clinics remain the most common option despite higher costs. For a detailed comparison between clinic and online evaluations, see our comprehensive online vs clinic comparison guide:
What's Included: In-person questionnaire, PLHCP review, basic vital signs (optional), written clearance, paper certificate
Time Required: 2-4 hours (including travel, waiting, appointment)
Additional Costs: Travel ($10-25), parking ($5-15), lost productivity (2-4 hours @ $25-50/hour = $50-200)
Total Real Cost: $165-390 per evaluation when all factors included
Mobile/On-Site Clinic: $125-200
Some companies bring mobile clinics to their facility to reduce employee travel time:
What's Included: On-site provider, group scheduling, immediate results
Minimum Requirements: Usually 10-25 employees minimum, advance scheduling required
Additional Costs: Travel fee ($200-500), facility setup, scheduling coordination
Best For: Large companies (100+ employees) in remote locations
Hidden Costs Most Companies Miss
The sticker price is only part of the true cost. Here are the hidden expenses that often exceed the evaluation fee itself:
| Hidden Cost | Online Eval | Clinic Visit |
|---|---|---|
| Employee Travel Time | $0 | $30-75 |
| Transportation Costs | $0 | $10-25 |
| Waiting Room Time | $0 | $15-40 |
| Scheduling Coordination | $5 | $20-50 |
| Result Processing Time | $0 | $10-30 |
| Total Hidden Costs | $5 | $85-220 |
Volume Pricing and Bulk Discounts
Most providers offer volume discounts for larger employers. Here's how pricing scales:
| Number of Employees | Online (RespiratorTest) | Clinic (Average) | Your Savings |
|---|---|---|---|
| 1-9 employees | $22/each | $125/each | $103/each |
| 10-49 employees | $22/each | $115/each | $93/each |
| 50-99 employees | $22/each | $110/each | $88/each |
| 100+ employees | $17/each | $100/each | $83/each |
| 500+ employees | $17/each | $95/each | $78/each |
ROI Calculator: Annual Savings by Company Size
Let's calculate real savings based on company size, assuming annual respirator medical evaluations:
50-Employee Company Annual Savings
Clinic Cost: 50 employees × $125 = $6,250
Hidden Costs: 50 employees × $150 avg = $7,500
Total Clinic Approach: $13,750/year
Online Cost: 50 employees × $22 = $1,100
Hidden Costs: 50 employees × $5 = $250
Total Online Approach: $1,350/year
Annual Savings: $12,400
(90% cost reduction)
Savings by Company Size
| Company Size | Clinic Annual Cost | Online Annual Cost | Your Annual Savings |
|---|---|---|---|
| 10 employees | $2,750 | $270 | $2,480 |
| 25 employees | $6,875 | $675 | $6,200 |
| 50 employees | $13,750 | $1,350 | $12,400 |
| 100 employees | $27,500 | $2,200 | $25,300 |
| 500 employees | $137,500 | $9,000 | $128,500 |
How to Reduce Costs Without Compromising Compliance
Here are proven strategies to dramatically lower your respirator medical evaluation costs while maintaining full OSHA compliance:
Strategy 1: Switch to Online Evaluations
Savings: 85-90%
The single most impactful change. Online evaluations cost $17-22 vs $75-150 at clinics. OSHA explicitly permits questionnaire-based evaluations without physical examination (1910.134(e)(4)), making online the most cost-effective compliant option.
Strategy 2: Eliminate Unnecessary Physical Exams
Savings: $50-100 per evaluation
OSHA does not require physical examinations for respirator clearance unless the PLHCP determines one is necessary after reviewing the questionnaire. Most employees (98%) don't need exams, yet many clinics include them by default, inflating costs unnecessarily.
Strategy 3: Negotiate Volume Discounts
Savings: 15-25% on large orders
If purchasing 100+ evaluations annually, negotiate bulk pricing. Online providers offer $17/evaluation for volume purchases. Even traditional clinics may discount 10-15% for large employer contracts.
Strategy 4: Optimize Evaluation Timing
Savings: Prevents duplicate evaluations
Schedule medical evaluations and fit testing together when possible to minimize disruption. Track expiration dates carefully - evaluations are valid for 12 months unless conditions change. Letting evaluations expire forces expensive emergency clinic visits.
Frequently Asked Questions
How much does a respirator medical evaluation cost?
Respirator medical evaluations cost $17-22 for online evaluations or $75-150 at traditional occupational health clinics. The price varies based on provider type, location, and whether physical examination is included. Online evaluations are OSHA-compliant and cost 85% less than clinic visits.
Are online respirator medical evaluations cheaper than clinic visits?
Yes, online respirator medical evaluations cost $17-22 compared to $75-150 at clinics. This represents savings of 85% on the evaluation cost alone. When factoring in travel time, lost productivity, and employee downtime, total savings often exceed 90%.
What are the hidden costs of clinic respirator evaluations?
Hidden costs include: employee travel time (1-2 hours), lost productivity ($30-75 per employee), transportation costs ($10-25), missed work scheduling, and potential overtime to cover absent workers. These hidden costs often exceed the evaluation fee itself.
Do volume discounts exist for respirator medical evaluations?
Yes, volume discounts are available. Online providers like RespiratorTest.com offer $17 per evaluation for purchases of 100+ certificates. Traditional clinics may offer 10-15% discounts for large employer contracts, but rates still remain significantly higher than online options.
Does insurance cover respirator medical evaluation costs?
Generally no. Respirator medical evaluations are considered employer-required occupational health screenings, not medical treatment. OSHA 1910.134 requires employers to provide evaluations at no cost to employees. Most health insurance plans exclude workplace-mandated screenings.
How much do companies save with online respirator evaluations?
A 50-employee company saves $6,400-13,900 annually by using online evaluations ($22) instead of clinic visits ($150-300). This includes direct cost savings plus recovered productivity. Larger companies with 500+ employees can save $64,000+ per year.
What is included in a respirator medical evaluation?
A standard respirator medical evaluation includes: OSHA Appendix C questionnaire completion, PLHCP (physician or licensed healthcare professional) review, medical clearance determination, written recommendation, and certificate of completion. Physical examination is only required if PLHCP determines it necessary.
Are cheaper respirator evaluations OSHA compliant?
Yes, if they meet OSHA 1910.134 requirements: use OSHA Appendix C questionnaire, reviewed by licensed PLHCP, provide written recommendation, and maintain proper documentation. Online evaluations at $17-22 meet all OSHA requirements and are accepted nationwide for compliance.
Ready to Save 90% on Respirator Medical Evaluations?
Complete OSHA-compliant evaluations online for $22. Instant PLHCP review, digital certificates, and 3-year record retention included.