Inspiratory Flow Rates During Hard Work When Breathing Through Different Respirator Inhalation and Exhalation Resistances

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There has been a long-standing debate regarding the adequacy of airflow rates used in respirator certification testing and whether these test flow rates underestimate actual values. This study investigated breath by breath inspiratory peak flow rate, minute ventilation, and instantaneous flow rates of eight young, healthy volunteers walking on a treadmill at 80–85% of maximal aerobic capacity until exhaustion while wearing an air-purifying respirator with one of eight combinations of inhalation and exhalation resistance. An analysis of variance was performed to identify differences among the eight conditions. Scheffe's post hoc analysis indicated which means differed. The group of conditions with the highest average value for each parameter was identified and considered to represent a worst-case scenario. Data was reported for these conditions. A Gaussian distribution was fit to the data and the 99.9% probability levels determined. The 99.9% probability level for the peak and instantaneous flow rates were 374 L/min and 336 L/min, respectively. The minute ventilation distribution was not Gaussian. Less than 1% of the recorded minute ventilations exceeded 135 L/min. Instantaneous flow rates exceeded the National Institute for Occupational Safety and Health's respirator test standards of 64, 85, and 100 L/min constant flow 91%, 87%, and 82% of the time, respectively. The recorded minute ventilations exceeded the 40 L/min minute ventilation test standard (for tests with a sinusoidal flow pattern) 100% of the time. This study showed that young, healthy respirator wearers generated peak flow rates, minute ventilations, and instantaneous flow rates that consistently exceeded current test standards. Their flow rates should be higher than those of a respirator wearer performing occupational work and could be considered upper limits. Testing respirators and respirator cartridges using a sinusoidal breathing pattern with a minute ventilation of 135 L/min (peak flow rate approximately 424 L/min) would encompass 99% of the recorded minute ventilations and 99.9% of the predicted peak and instantaneous flow rates from this study and would more accurately reflect human respiration during strenuous exercise.