What is a Respirator Medical Evaluation? (Get Yours Online for $17)
Dr. Nader Mikhail
10 min read
Updated: January 14, 2025
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If your employees wear respirators for work — whether N95 masks, half-face respirators, or full-face respirators — OSHA requires a medical evaluation before they can use them. This isn't optional bureaucracy; it's a critical safety step that protects workers from serious health complications.
The good news? You don't need to send employees to expensive clinics anymore. Modern online respirator medical evaluations meet all OSHA requirements at a fraction of the cost and time.
What Exactly is a Respirator Medical Evaluation?
A respirator medical evaluation is a health screening mandated by OSHA regulation 1910.134(e) to determine whether an employee is physically capable of performing work while wearing a respirator. The evaluation identifies medical conditions that could make respirator use dangerous, such as:
- Heart conditions (arrhythmia, hypertension, coronary artery disease)
- Lung problems (asthma, COPD, emphysema, reduced lung capacity)
- Chronic conditions that affect breathing or exertion
- Claustrophobia or anxiety disorders triggered by mask use
- Pregnancy or medical treatments affecting respiratory capacity
Unlike a routine physical exam, the respirator medical evaluation is job-specific. The healthcare professional considers:
• Type of respirator: N95 filtering facepiece, half-face elastomeric, full-face SCBA, etc.
• Work environment: Temperature, humidity, physical exertion level
• Duration of use: Continuous wear vs. intermittent use
• Workplace hazards: Chemical exposure, dust levels, oxygen deficiency
Why OSHA Requires Medical Evaluations
Respirators restrict airflow and increase breathing resistance. For healthy individuals, this causes minimal discomfort. But for workers with underlying heart or lung conditions, wearing a respirator can lead to:
OSHA's medical evaluation requirement protects both employees and employers from these risks. It also shields companies from liability if a worker experiences health problems while wearing a respirator.
Learn more about complete OSHA 1910.134 medical evaluation requirements.
How Does a Respirator Medical Evaluation Work?
The evaluation process involves three key components:
1. OSHA Appendix C Questionnaire
The employee completes the OSHA Appendix C questionnaire — a standardized 45-question form covering:
• Section 1: Job and respirator type information (completed by employer)
• Section 2: Medical history including heart, lung, and chronic conditions
• Section 3: Work environment factors (temperature, exertion, duration)
The questionnaire is confidential. OSHA requires that only the reviewing healthcare professional sees the employee's medical responses — employers only receive clearance status (approved, approved with limitations, or not approved).
2. PLHCP Review
A Physician or other Licensed Healthcare Professional (PLHCP) reviews the completed questionnaire. The PLHCP can be:
- Physician (MD or DO)
- Physician Assistant (PA)
- Nurse Practitioner (NP)
- Other licensed healthcare professionals permitted by state law
Important: OSHA does NOT require an in-person physical examination unless the PLHCP determines one is necessary after reviewing the questionnaire. In fact, 98% of employees receive clearance based on questionnaire review alone, without any physical exam. Learn more about PLHCP qualifications for respirator evaluations.
3. Written Recommendation
After review, the PLHCP provides a written recommendation to the employer, stating:
✅ Cleared: Employee is medically able to wear the specified respirator
⚠️ Cleared with limitations: Employee approved for certain respirator types only (e.g., powered air-purifying respirator instead of N95)
❌ Not cleared: Employee cannot wear a respirator due to medical contraindications
The employer receives a certificate of medical clearance but does NOT receive details about the employee's medical history (HIPAA protection).
Traditional Clinic vs. Online Evaluation: Cost & Time Comparison
For decades, the only option was sending employees to occupational health clinics. But online platforms now offer OSHA-compliant evaluations at 85% lower cost and 90% less time:
| Factor | Traditional Clinic | Online Evaluation |
|---|---|---|
| Cost | $75-150 per evaluation | $17-22 per evaluation |
| Time Required | 2-4 hours (travel + waiting + appointment) | 10-15 minutes |
| Travel Needed | Yes — employees leave worksite | No — complete from anywhere |
| PLHCP Review | In-person or telehealth after visit | Physician-developed algorithms + MD review for flagged cases |
| Results Delivery | 3-7 days (mailed or faxed) | Instant (98% of cases) |
| Physical Exam | Often included (not OSHA-required) | Only if PLHCP determines necessary |
| Record Retention | Paper files (manual tracking) | 30-year digital retention |
| OSHA Compliance | ✅ Compliant | ✅ Fully Compliant |
Real-World Savings Example
A construction company with 75 employees requiring annual respirator evaluations:
- Clinic approach: 75 × $125 (clinic fee) + $8,250 (lost productivity) = $17,625/year
- Online approach: 75 × $22 = $1,650/year
- Annual savings: $15,975 (91% cost reduction)
See detailed cost breakdowns in our complete pricing guide or compare clinic vs. online evaluations.
When is a Respirator Medical Evaluation Required?
OSHA 1910.134(e)(1) requires medical evaluations in the following situations:
- Before Initial Respirator Use
All employees must be evaluated BEFORE wearing any respirator, including N95s for voluntary use
- Before Fit TestingMedical clearance must be obtained before conducting fit tests. Learn more about fit test vs. medical evaluation timing
- Annually
Reevaluations at least once every 12 months, even if conditions haven't changed
- When Health Changes Occur
New diagnosis, surgery, pregnancy, medication changes, or observable breathing difficulties
- When PLHCP Recommends
If previous evaluation included a recommendation for follow-up assessment
- When Work Conditions Change
Increased physical effort, higher temperatures, longer wear duration, or new respirator type
How RespiratorTest.com Works: Get Certified in 3 Steps
Purchase Evaluation Credits ($17-22/employee)
Select the number of employees needing evaluations. Volume discounts available (100+ evaluations = $17/each). No subscription fees or hidden costs.
Employees Complete OSHA Questionnaire (10-15 Minutes)
Workers access the platform with their unique code and complete the confidential OSHA Appendix C questionnaire from any device. No travel, no appointments, no waiting rooms.
Instant PLHCP-Approved Certificate (98% of Cases)
Our physician-developed system evaluates responses instantly. Clear responses receive immediate clearance. Flagged responses route to our Medical Review Officer (licensed physician) for review within 24 hours. Digital certificate downloads immediately.
✅ OSHA Compliant | 💰 85% Cost Savings | ⚡ 15-Minute Completion
Join 1,200+ companies who've eliminated clinic visits. Get instant medical clearance for $17/employee.
Trust & Compliance: Why Employers Choose RespiratorTest.com
Full OSHA 1910.134 Compliance
Our platform uses the exact OSHA Appendix C questionnaire with licensed physician (PLHCP) review. Meets all federal and state respiratory protection requirements. Accepted nationwide for compliance.
Licensed Medical Review Officer (MRO) Oversight
All evaluations reviewed by Dr. Nader Mikhail, MD — board-certified physician with occupational health expertise. Flagged cases receive direct physician consultation within 24 hours.
HIPAA-Compliant & SOC 2 Certified
Enterprise-grade security protects employee health information. Encrypted data storage, HIPAA-compliant record handling, and SOC 2 Type II certification for data security and privacy.
30-Year Digital Record Retention
OSHA requires employers to retain medical evaluation records for the duration of employment. We store certificates digitally for 30 years with instant access for audits. No file cabinets or lost paperwork.
Frequently Asked Questions
What is a respirator medical evaluation?
A respirator medical evaluation is an OSHA-mandated health assessment to determine if an employee is medically able to safely wear a respirator. It involves completing the OSHA Appendix C questionnaire reviewed by a licensed healthcare professional (PLHCP). The evaluation identifies health conditions that could make respirator use unsafe, such as heart or lung problems.
How much does a respirator medical evaluation cost?
Online respirator medical evaluations cost $17-22 and take 15 minutes. Traditional clinic visits cost $75-150 and require 2-4 hours including travel and waiting. Online evaluations are OSHA-compliant, provide instant results, and include PLHCP review.
Is a respirator medical evaluation required by OSHA?
Yes. OSHA 1910.134(e) requires employers to provide a medical evaluation before an employee uses a respirator, during initial fit testing, annually, and when health changes occur. Employers must pay for evaluations and conduct them during work hours.
Can respirator medical evaluations be done online?
Yes. OSHA explicitly permits online questionnaire-based medical evaluations. Physical examinations are only required if the PLHCP determines one is necessary after reviewing responses. 98% of employees receive instant clearance online without clinic visits.
How long does a respirator medical evaluation take?
Online evaluations take 10-15 minutes to complete with instant results for 98% of employees. Traditional clinic visits require 2-4 hours including travel, waiting, and appointment time. Online evaluations eliminate travel and scheduling delays.
Who reviews respirator medical evaluations?
A Physician or other Licensed Healthcare Professional (PLHCP) must review all respirator medical evaluations. This includes physicians (MD/DO), nurse practitioners, physician assistants, or other licensed professionals permitted to provide medical evaluations under state law.
How often are respirator medical evaluations required?
Respirator medical evaluations are required: (1) Before initial respirator use, (2) Annually, (3) When the PLHCP, supervisor, or employee believes reevaluation is necessary, and (4) When observations during fit testing suggest health concerns.
What happens if an employee fails a respirator medical evaluation?
If medically cleared with limitations, the PLHCP specifies which respirator types are safe. If not cleared, the employee cannot wear a respirator until health conditions improve. The PLHCP may recommend re-evaluation after medical treatment or recommend workplace controls that eliminate respirator need.
Ready to Eliminate Clinic Visits? Start for $17
OSHA-compliant respirator medical evaluations completed online in 15 minutes. Instant PLHCP-approved certificates. No travel, no waiting, no hassle.
Related Articles
→ How Much Does a Respirator Medical Evaluation Cost? [2025 Pricing Guide]
→ Clinic vs. Online Respirator Medical Evaluations: Cost & Compliance Comparison
→ OSHA Appendix C Respirator Questionnaire Guide
→ OSHA 1910.134 Medical Evaluation Requirements Explained
→ Complete Your Online Respirator Medical Evaluation Now