Respiratory Protection: Complete Buyer's Guide (2026)

Last updated: June 10, 2026  ·  Reading time: ~18 min  ·  By: Steven Eaton, WC Safety Editorial

Respiratory Protection: Complete Buyer's Guide (2026)

The short answer: respiratory protection means selecting a NIOSH-approved respirator with an Assigned Protection Factor (APF) high enough to reduce a worker's airborne exposure to or below the applicable OSHA permissible exposure limit — and backing that equipment with a written respiratory protection program, medical evaluation, and annual fit testing. For most industrial and construction applications, a full-face air-purifying respirator (APF 50) from the 3M full-face mask respirator lineup paired with the right cartridge covers the widest range of hazards at the lowest maintenance burden. This guide explains the regulatory framework, selection process, and maintenance requirements from end to end.

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1 — What is respiratory protection?

Respiratory protection is the use of NIOSH-approved respiratory protective equipment (RPE) to reduce a worker's inhalation exposure to airborne contaminants — particulates (dust, fume, mist, fiber), gases and vapors (solvents, acids, carbon monoxide), biological aerosols, and oxygen-deficient atmospheres — to concentrations at or below established occupational exposure limits (OELs). It is always the last line of defense in the industrial hygiene hierarchy of controls: engineering controls (ventilation, substitution, enclosure) come first; administrative controls (exposure rotation, scheduling) come second; respiratory protection protects workers only when the first two tiers are infeasible or insufficient.

The respiratory protection regulatory framework in the United States is three layers deep. At the device level, the National Institute for Occupational Safety and Health (NIOSH) certifies respirators under 42 CFR Part 84 — assigning a TC approval number to every device that passes efficiency and construction testing. At the program level, OSHA mandates the conditions under which those devices must be used under 29 CFR 1910.134 (general industry) and 29 CFR 1926.103 (construction). At the best-practice level, ANSI/ISEA Z88.2 provides the professional framework that safety practitioners use to build programs that exceed the regulatory minimum.

Why respiratory protection is a last resort — not a first response

OSHA 1910.134(a) is unambiguous: respirators are to be used where "feasible engineering and administrative controls do not adequately protect employees." This hierarchy matters practically — an employer who specifies P100 filters for every worker rather than installing adequate exhaust ventilation is simultaneously non-compliant with the hierarchy-of-controls requirement and over-spending on disposables. The rule of thumb: if engineering controls can get airborne concentrations below the action level, implement them. If they can only get to 1–5× the PEL, pair them with respiratory protection. If concentrations are above the IDLH value, no air-purifying respirator is adequate — a supplied-air system is mandatory.

Who needs a formal respiratory protection program

Any employer who requires workers to wear respirators — or who permits voluntary respirator use of anything other than a filtering facepiece — must maintain a written respiratory protection program under 1910.134(c). This covers a wider population than most employers expect: construction contractors grinding concrete, manufacturing maintenance teams degreasing parts, painting contractors applying solvent-based coatings, agricultural workers applying pesticides, and laboratory workers handling volatile chemicals all fall within scope. The written program obligation is not optional — it is the administrative backbone that makes every other program element enforceable.

2 — Types of respirators: APR, PAPR, and supplied-air

NIOSH and OSHA classify respirators by their mode of protection: air-purifying respirators (APRs) remove contaminants from ambient air; atmosphere-supplying respirators deliver clean air from an independent source. Each type has a defined Assigned Protection Factor (APF) that governs when it may be used.

Air-purifying respirators: half-face and full-face

APRs are the workhorse of industrial respiratory protection. They use filter media, chemical sorbent cartridges, or both to clean ambient air as the worker inhales. The facepiece design determines the APF:

• Half-face APR (APF 10): covers nose and mouth; relies on N95, R95, P100, or OV/combination cartridges. Correct for exposures below 10× the applicable OEL. The most common specification for moderate-hazard industrial tasks — light degreasing, general construction dust, welding fume at low concentrations.
• Full-face APR (APF 50): covers nose, mouth, and eyes; provides integrated eye and face protection alongside respiratory protection. Correct for exposures up to 50× the OEL. Required for high-silica construction operations, asbestos Class I/II abatement, and any task where chemical splash to the eyes is also a concern. The 3M 6000 Series, 3M 7800 Series, and 3M Ultimate FX FF-400 Series are the three 3M full-face APR families stocked on this site.

Powered air-purifying respirators (PAPRs)

PAPRs use a battery-powered blower to pull air through filter media and deliver it to the facepiece at positive pressure. Because the airflow is positive — pushing out rather than relying on seal — PAPRs with loose-fitting hoods or helmets do not require fit testing. APFs range from 25 (loose-fitting facepiece) to 1,000 (tight-fitting full-face or hood/helmet). PAPRs are the correct specification for workers who cannot achieve an adequate seal on a tight-fitting APR — workers with facial hair, unusual facial geometry, or workers in hot environments where the motorized airflow significantly reduces heat stress.

Supplied-air respirators (SAR) and SCBA

Atmosphere-supplying respirators deliver Grade D or better breathing air from a compressor, compressed cylinder, or SCBA tank. They are required for IDLH atmospheres, oxygen-deficient environments (below 19.5% O₂), and any situation where the contaminant concentration exceeds the MUC of available APRs. SARs in continuous-flow mode with a full-face facepiece carry an APF of 1,000; pressure-demand SCBAs carry an APF of 10,000. These are the respirators required for confined-space entry with unknown atmospheres, emergency response, and any operation in immediately hazardous conditions.

Filtering facepieces: N95, KN95, and what they are not

Filtering facepiece respirators (FFRs) — N95s, R95s, P100 disposables — are the most widely used class of respirator. An N95 disposable carries an APF of 10 when used in a required program with medical evaluation and fit testing, or may be worn voluntarily with only Appendix D information. Important distinctions: KN95 respirators are certified to China's GB2626 standard, not NIOSH 42 CFR Part 84 — they do not satisfy the NIOSH-approval requirement of OSHA 1910.134(d)(1)(ii) and may not be used in required programs. Surgical masks carry no NIOSH approval, no APF, and are not respiratory protection under any OSHA standard. See the NIOSH approval label guide for how to verify a respirator's certification on the label.

Full-face APR comparison: 3M 6000 vs 7800 vs Ultimate FX

All three 3M full-face series carry an APF of 50 and are compatible with 3M's bayonet-mount cartridge system (with some model-specific exceptions for the FF-400 series). The choice between them is driven by work environment, wear duration, and budget:

For deeper guidance on choosing between these three series, see the best 3M full-face respirator buyer's guide.

3 — How to choose the right respirator

Respirator selection is a four-step process that starts with the hazard and ends with a NIOSH-approved device whose APF yields a Maximum Use Concentration (MUC) above the measured or estimated exposure level. Skipping steps — or choosing equipment based on what's available in the supply room — is both a compliance failure and a real worker protection failure.

Step 1 — Identify the hazard class

Is the hazard particulate (dust, fume, mist, fibers), gas/vapor (solvents, acid gases, CO), biological aerosol, oxygen deficiency, or a combination? Each class requires different filter media or cartridge chemistry. Particulate hazards require NIOSH-rated filter efficiency (N, R, or P class at 95, 99, or 100%). Gas and vapor hazards require chemical sorbent cartridges matched to the specific contaminant family. Mixed hazards require combination cartridges. The Safety Data Sheet (SDS) Section 8 lists the recommended respiratory protection for each product — this is the starting point for contaminant identification.

Step 2 — Determine the exposure concentration

Personal air monitoring — industrial hygiene air sampling — is the most defensible basis for respirator selection. The 8-hour TWA result is compared against the applicable OEL: OSHA PEL (legally binding minimum), NIOSH REL (more conservative in many cases), or ACGIH TLV (often the most protective). ANSI/ISEA Z88.2 recommends using the most protective applicable OEL when multiple standards exist for the same substance. When personal monitoring has not been performed, OSHA default estimates, historical monitoring data from similar operations, or published control banding tools may be used to bracket the expected exposure range — but measured data is always preferred for selecting equipment that will actually protect the worker.

Step 3 — Apply the OSHA APF table to calculate the required APF

Divide the measured or estimated exposure by the applicable OEL. The result is the minimum required APF. If the ratio is 8 (exposure is 8× the OEL), the minimum required APF is 10 — a half-face APR satisfies the requirement. If the ratio is 30, the minimum required APF is 50 — a full-face APR or half-face PAPR is the minimum specification. If the ratio exceeds 50 but is below 1,000, a full-face PAPR or hood-type PAPR is required. If the ratio exceeds 1,000, or if conditions are IDLH, a supplied-air or SCBA system is required — no air-purifying respirator is adequate regardless of filter efficiency.

Step 4 — Select a NIOSH-approved device meeting the required APF

Confirm the selected respirator has a current TC approval number on the NIOSH Certified Equipment List (CEL). Match the cartridge or filter to the contaminant class. Document the selection — including the APF basis, the specific NIOSH-approved model, the TC approval number, and the cartridge change-out schedule — in the written respiratory protection program. Browse the complete 3M full-face mask respirator collection for APF-50 options, or the 3M cartridges and filters collection for cartridge selection across the full hazard spectrum.

4 — OSHA respiratory protection requirements

OSHA's respiratory protection requirements operate at two levels: a general industry baseline standard (1910.134) and construction-specific requirements (1926.103) that incorporate 1910.134 by reference, supplemented by substance-specific standards for the highest-risk construction exposures.

29 CFR 1910.134 — general industry baseline

The OSHA 1910.134 respiratory protection standard establishes the compliance floor for all general industry employers. Its core requirements are: (1) written respiratory protection program for all required-use programs and most voluntary-use scenarios; (2) NIOSH-approved equipment only; (3) medical evaluation before first use via the Appendix C questionnaire and PLHCP clearance; (4) annual fit testing for all tight-fitting respirators using Appendix A protocols; (5) user seal checks before each use; (6) documented cartridge change-out schedules with objective basis; (7) initial and annual training; and (8) records retention for fit tests and medical evaluations. OSHA's 2006 APF Final Rule codified the APF table as a mandatory selection tool — every respirator must now be matched to a hazard using APF and MUC, not just filter class.

29 CFR 1926.103 — construction

Construction employers comply with 1926.103 by satisfying all requirements of 1910.134. Construction respiratory protection programs are identical to general industry programs in administrative structure; the differences lie in the substance-specific standards that overlay the 1910.134 baseline for silica, asbestos, and lead. Construction also presents specific practical challenges: high workforce turnover, multi-employer worksites, workers who may have fit tests on file from previous employers, and rapidly changing hazard profiles as tasks shift from day to day.

Substance-specific standards: silica, asbestos, and lead

Three construction substance-specific standards add requirements on top of 1910.134 / 1926.103:

• Silica (1926.1153): Effective June 2017. PEL 50 µg/m³ (8-hr TWA); action level 25 µg/m³. Table 1 engineering controls can satisfy the standard without air monitoring for specified tasks — the practical compliance route for most construction grinding, cutting, and drilling operations. Respiratory protection required above the PEL: half-face APR with P100 (MUC 500 µg/m³) or full-face APR with P100 (MUC 2,500 µg/m³). The 3M 2091 P100 filter on a full-face chassis is the standard specification for high-concentration silica operations.
• Asbestos (1926.1101): PEL 0.1 f/cc (1-hr TWA). Class-based respiratory protection requirements: Class III/IV work — half-face APR with P100 minimum; Class I/II work — full-face APR with P100 minimum; certain Class I operations — PAPR or supplied-air required.
• Lead (1926.62): PEL 50 µg/m³; action level 30 µg/m³. APF-based selection: above PEL to 500 µg/m³ — half-face APR with P100; above 500 µg/m³ — full-face APR minimum. Lead burning and cutting operations may require combination OV/P100 cartridges for fume components.

5 — Written program, fit testing, and medical evaluation

The written respiratory protection program (WRPP) is the administrative framework that makes everything else legally enforceable. Without it, fit tests and medical evaluations exist in isolation — they cannot be audited, cannot be updated when conditions change, and cannot demonstrate systematic compliance to an OSHA inspector. The WRPP is also the document that program administrators (ideally a Certified Industrial Hygienist, per ANSI/ISEA Z88.2) use to document every selection decision and ensure the program evolves with the workplace.

The eight WRPP elements under 1910.134(c)(1)

The WRPP must include worksite-specific procedures for: (1) respirator selection — hazard basis, APF calculation, NIOSH-approved model, TC number; (2) medical evaluation — PLHCP, questionnaire administration, clearance documentation; (3) fit testing — protocol, administrator, frequency, records; (4) respirator use — seal checks, facial hair policy, IDLH procedures; (5) maintenance and care — cleaning, inspection, storage, replacement criteria; (6) breathing air quality (for supplied-air programs); (7) training — initial and annual, language requirements; and (8) program evaluation — monitoring effectiveness, update triggers. A WRPP that lists these headings but has no worksite-specific content under them fails the standard.

Medical evaluation: what the PLHCP must know

Medical evaluation under §1910.134(e) is triggered before first required respirator use. The Appendix C questionnaire is completed privately by the employee and sent directly to the PLHCP — the employer sees only the clearance recommendation, not the questionnaire content. The PLHCP's recommendation states whether the employee is cleared, cleared with restrictions, or not cleared for the specified respirator type. Per ANSI/ISEA Z88.2, providing the PLHCP with a task-specific briefing — describing the respirator's physical demands, work intensity, environmental conditions, and duration of use — significantly improves the quality of the clearance decision. Without this context, the PLHCP is clearing the employee for "wearing a respirator," not for wearing a specific piece of equipment during heavy outdoor work at high temperature for six hours continuously.

Fit testing: annual obligation and Appendix A protocols

Annual fit testing is required for all tight-fitting respirators in required programs. The test must be performed on the specific model the worker will use — a fit test on a medium 3M 6800 does not cover the 3M 7800S or the 3M FF-402. OSHA Appendix A accepts four qualitative protocols (isoamyl acetate, saccharin, Bitrex, irritant smoke) for half-face APRs (APF 10), and three quantitative protocols (generated aerosol, CNC, CNP) for any respirator. The minimum pass threshold for quantitative testing is a fit factor of 100 for half-face and 500 for full-face. Fit test records must be retained until the next test is performed and must include the worker's name, test date, protocol, respirator model/size/TC number, and pass/fail result.

6 — Respirator cartridge and filter selection

Cartridge and filter selection is where the chemistry of the contaminant meets the physics of the NIOSH approval system. Selecting the wrong cartridge — an OV cartridge for a formaldehyde exposure, for example, or an N95 for an oil-mist environment — provides no protection for that specific hazard regardless of the APF the respirator class carries. The SDS, industrial hygiene data, and the NIOSH 42 CFR Part 84 N/R/P classification system are the three inputs that determine the correct specification.

Particulate filters: N, R, and P classes

Under 42 CFR Part 84, particulate filter classes are defined by efficiency level and oil resistance:

• N-class (Not oil-resistant): 95, 99, or 100% efficiency against non-oil aerosols. N95 is the standard specification for oil-free particulate environments — construction dust, wood dust, grain dust, bioaerosols. N-class filters degrade rapidly when exposed to oil aerosols and must not be used where oil mists are present.
• R-class (oil-Resistant): 95, 99, or 100% efficiency; maintains performance in oil-aerosol environments for a single shift (change at end of shift or 8 hours). Limited applicability — the R-series is largely superseded in practice by P-class.
• P-class (oil-Proof): 95, 99, or 100% efficiency; no degradation from oil aerosols. The 3M 2091 P100 filter and the 3M 7093 P100 cartridge are P100-rated — 99.97% minimum efficiency, oil-proof. Required for metal fume, silica, asbestos, and any particulate in an oil-mist environment. Service life is based on breathing resistance increase, not chemical exhaustion.

See the NIOSH 42 CFR Part 84 guide for the full N/R/P classification framework and efficiency tier detail.

Gas and vapor cartridges: OV, acid gas, and multi-gas

Gas and vapor cartridges contain activated carbon or other chemical sorbents that adsorb specific contaminant families from inspired air. The cartridge chemistry must match the contaminant — an organic vapor (OV) cartridge for petroleum solvents and most aromatic hydrocarbons; an acid gas cartridge for HCl, SO₂, HF, and Cl₂; an ammonia/methylamine cartridge for alkaline gases; a formaldehyde cartridge for formaldehyde and other aldehydes. For operations involving multiple gas families simultaneously — welding on coated steel, spray painting with acid-cure coatings, chemical mixing — a multi-gas or combination cartridge is required. The 3M 6001 OV cartridge and 3M 6003 OV/acid gas cartridge cover the two most common gas-phase industrial hazard profiles.

Combination OV/P100 and multi-gas/P100 cartridges

When both gas/vapor and particulate hazards are present simultaneously — spray painting (solvent vapor + paint mist), welding on coated steel (metal fume + coating vapors), spray-applied pesticides (organic vapor + fine particulate) — a combination cartridge addressing both hazard classes is required. The cartridge must be specified in the written program as the selected respirator for that task. Options across the 3M lineup:

• 3M 60921 OV/P100 — organic vapor + P100 particulate; standard specification for solvent painting with a full-face APR
• 3M 60923 OV/acid gas/P100 — adds acid gas coverage; correct for polyurethane coatings and isocyanate-containing products where HCN or acid gas byproducts are possible
• 3M 60926 multi-gas/P100 — broadest coverage; correct for chemical manufacturing operations with multiple gas families and particulate
• 3M 6006 multi-gas cartridge (without integrated P100) — covers OV, acid gas, and multiple vapor families; pair with a separate P100 pre-filter when particulate is also present

Cartridge change-out: ESLI vs. calculated schedule

OSHA 1910.134(d)(3)(iii)(B) requires a documented change-out schedule for OV and combination cartridges with an objective basis. Two approaches satisfy the requirement: (1) an End-of-Service-Life Indicator (ESLI) on the cartridge signals exhaustion in real time — NIOSH requires ESLI on OV cartridges where technically feasible; (2) a calculated schedule based on contaminant concentration, work rate, temperature, and humidity using 3M's Service Life Software or equivalent mathematical model. A schedule that says "replace every shift" without a documented calculation is a citable deficiency under 1910.134. The 3M 2097 P100 with nuisance OV relief is a common specification where organic vapor concentrations are low (nuisance level) and a full OV cartridge change-out schedule is not warranted.

7 — Maintenance, storage, and replacement

A NIOSH-approved respirator that is damaged, improperly stored, or used past its service life provides no APF — it is just a face covering. Maintenance and care under §1910.134(h) are not administrative formalities; they are the mechanical requirements that maintain the seal, filter performance, and valve function that the APF rating assumes.

Cleaning, inspection, and storage

Reusable facepieces (all three 3M full-face series) must be cleaned and disinfected at a frequency that prevents worker health impairment — at minimum after each use, and more frequently in hot, humid, or high-particulate environments. OSHA Appendix B-2 provides cleaning procedures. Inspection before each use covers: facepiece condition (no cracks, tears, or deformations that would affect seal); headstraps (no broken or stretched bands); valves (inhalation and exhalation valves seat fully and are not distorted); lens (clear, no cracks); cartridge connections (secure, no cross-threading). Damaged respirators must be removed from service immediately — they must not be patched, taped, or improvised. Storage must protect from UV light, dust, chemicals, temperature extremes, and physical deformation — storing a full-face APR in a way that distorts the facepiece shape permanently affects fit and seal.

When to replace cartridges and filters

Replacement triggers vary by cartridge type:

• P100 particulate filters (3M 2091, 3M 7093): replace when breathing resistance increases noticeably during use, when physically damaged, or when loaded with visible particulate. No chemical exhaustion mechanism — P100 filters become more efficient as they load, until resistance becomes uncomfortable. Change-out is driven by work rate and particulate loading, not a fixed time interval.
• OV and combination cartridges: replace per the documented change-out schedule (ESLI or calculated interval). Change immediately if solvent odor is detected inside the facepiece — this indicates breakthrough, which means the cartridge is exhausted and the worker is being exposed. Do not rely on odor as the primary change-out signal — many solvents have OELs below odor threshold, meaning breakthrough detection by smell is too late.
• Combination OV/P100 cartridges: the P100 component and the OV component have independent service lives. Replace the entire cartridge when either component reaches its end of service life — whichever comes first. This means a combination cartridge used in a high-particulate, low-solvent environment may need replacement for particulate loading before the OV sorbent is exhausted.

Facepiece replacement and total cost of ownership

Reusable facepieces have no fixed replacement interval — they are replaced when inspection reveals damage that cannot be corrected by part replacement (straps, valves, lens covers are available as replacement components for all 3M series). In multi-worker programs, tracking facepiece assignment to individual workers is important: fit tests are performed on a specific model assigned to a specific worker, and sharing facepieces requires re-fit-testing each new user. The economics of replacement vs. disposable filtering facepiece programs favor reusable full-face APRs for workers with frequent high-exposure tasks — the cartridge cost per shift is lower than a disposable N95 for equivalent or greater protection, and the full-face APR additionally eliminates the need for a separate face shield in chemical environments. For program-level cost analysis and product comparison, see the best 3M full-face respirator buyer's guide.

8 — Respirator recommendations by hazard type

The right respirator for any given task is determined by the APF requirement, the contaminant type, and the work environment. Here are the standard specifications for the highest-frequency industrial and construction hazard scenarios, all using NIOSH-approved equipment stocked on this site:

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Concrete grinding and silica (OSHA 1926.1153)

Exposures above 500 µg/m³ (above half-face MUC) require a full-face APR with P100. Standard specification: 3M 6000 Series full-face + 3M 2091 P100 filter.

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Solvent spray painting (OV + particulate)

Organic vapor from solvent carrier + paint mist from spray process requires a combination OV/P100. Standard specification: 3M full-face APR + 3M 60921 OV/P100 cartridge.

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Welding and metal cutting (metal fume)

Iron oxide and metal fume at low concentrations: half-face APR with 3M 2097 P100 with OV nuisance relief. Welding on coated or stainless steel with organic vapor / acid gas components: full-face APR with 3M 60923 OV/acid gas/P100.

Solvent degreasing (organic vapor only)

No significant particulate — vapor only. Half-face APR with 3M 6001 OV cartridge for low-to-moderate concentrations. Multi-solvent environments: 3M 6006 multi-gas cartridge.

Frequently asked questions about respiratory protection

Related guides and reference pages

This pillar guide hubs to the following cluster pages covering specific regulatory, product, and selection topics in depth:

• NIOSH 42 CFR Part 84 respirator certification guide — N/R/P classification, TC approval numbers, CEL verification workflow, and the certification framework every respirator selection must reference.
• OSHA 29 CFR 1910.134 respiratory protection standard guide — full walkthrough of the general industry standard: every section, the APF table, Appendix A fit test protocols, and common citation patterns.
• OSHA 29 CFR 1926.103 construction respiratory protection guide — how the construction standard incorporates 1910.134, silica and asbestos rules, and a concrete grinding compliance worked example.
• OSHA 29 CFR 1926.1153 construction silica standard guide — Table 1 engineering controls for concrete grinding, cutting, tuckpointing, and jackhammering; written exposure control plans; medical surveillance triggers; and P100 respirator requirements.
• ANSI/ISEA Z88.2 respiratory protection program standard guide — the professional consensus standard above the OSHA minimum: cartridge change-out calculations, program administrator qualifications, and multi-hazard program design.
• How to read a NIOSH approval label — field guide to verifying that a respirator on the job site carries a legitimate NIOSH certification.
• Best 3M full-face respirator buyer's guide — side-by-side comparison of the 3M 6000, 7800, and Ultimate FX series for APF-50 applications.
• 3M full-face mask respirator collection — complete lineup of NIOSH-approved full-face APRs (APF 50) stocked for immediate shipping.
• 3M respirator cartridges and filters collection — P100, OV/P100, acid gas/P100, and multi-gas cartridges covering the full respiratory hazard spectrum.
• 3M 2091 P100 respirator filter review — detailed performance and compatibility review of the standard P100 particulate filter for silica and asbestos operations.
• Respirator fit testing guide — QLFT vs QNFT protocols, pass/fail thresholds (fit factor ≥100 half-face / ≥500 full-face), 1910.134(f) annual testing requirements, and record retention.
• Respirator cartridge change-out schedule guide — ESLI vs calculated schedule selection, 3M Service Life Software inputs, 10 SKU-level cartridge decode table, and OSHA 1910.134(d)(3)(iii)(B) documentation requirements.
• ACGIH TLVs vs OSHA PELs respirator selection guide — why most Z-table PELs are outdated since 1971, how TLVs drive stricter APF selection, and how to document OEL choice in the WRPP per ANSI Z88.2.