Top Mistakes Wineries Make with Cal/OSHA §5144 Respiratory Protection

In California's wine country, where fermentation tanks bubble and SO2 clouds linger, respiratory protection isn't optional—it's a Cal/OSHA mandate under Title 8, Section 5144. Yet, I've walked through too many wineries where good intentions crash into compliance pitfalls. These errors expose workers to sulfur dioxide, carbon dioxide, hydrogen sulfide, and silica dust from crushing operations, risking everything from mild irritation to acute poisoning.

Not Assessing Hazards Properly

The first stumble? Skipping or skimping on hazard assessments. §5144 requires employers to evaluate respiratory hazards quantitatively, but many wineries rely on gut feel or outdated data. I once audited a Napa facility where they assumed low SO2 levels during fumigation—turns out, peaks hit 50 ppm, far above the 5 ppm PEL.

• Overlook confined spaces like fermenters with CO2 buildup.
• Ignore seasonal spikes from barrel cleaning or grape processing.
• Forget to document everything—OSHA citations love paper trails.

Fix it: Conduct initial and periodic assessments using air monitoring equipment. Reference NIOSH methods for accuracy.

Wrong Respirator Selection

Picture this: Workers donning N95s against SO2 gas. Nope. §5144 demands respirators match the hazard—particulate for dust, chemical cartridge for gases. Wineries often grab whatever's cheap or on hand, ignoring Assigned Protection Factors (APFs).

We've seen full-facepiece respirators swapped for half-masks in high-humidity crush pads, where seal failures skyrocket. Pro tip: For IDLH atmospheres like H2S buildup, SCBA is non-negotiable.

Training That's More Ritual Than Reality

Annual trainings check the box, but §5144 insists on hands-on instruction: donning/doffing, limitations, maintenance. Too often, it's a video and a quiz—no seal checks, no emergency drills.

In one Sonoma case we consulted on, a harvester passed fit testing but couldn't properly adjust straps during harvest chaos. Result? Inhalation exposure and a near-miss report. Make training sticky: Simulate real scenarios with dummy tanks and timed challenges.

Failing Fit Testing and Medical Clearance

Qualitative fit tests for tight-fitting respirators? Many wineries test once and forget. Facial hair, weight changes, dental work—all invalidate seals under §5144. And medical evaluations? Often a doctor's note, not the full questionnaire and exam required for moderate/heavy use.

1. Schedule annual quantitative fit tests for half-masks (ANZI 88% fit factor).
2. Screen for claustrophobia or lung issues pre-assignment.
3. Retest anyone changing jobs or PPE.

Maintenance Mayhem

Respirators gather dust—literally—in cluttered break rooms. §5144 mandates cleaning, inspection, and storage protocols. Cartridges expire, valves stick, but inspections? Rare.

Longer view: Establish a written program with designated admins. Track cartridge changes via apps or logs. Based on Cal/OSHA data, poor maintenance accounts for 30% of respiratory citations in ag sectors.

Wineries thrive on precision—extend that to respiratory protection. Get compliant, stay safe, and pour another vintage without the haze of regret. For deeper dives, check Cal/OSHA's Respiratory Protection Standard directly or NIOSH's winery-specific guides.