This study evaluated performance of individuals exercising at a fixed workl
oad and wearing full-facepiece respirators modified to provide expiratory r
esistances of 0.27, 0.47, 1.81, 4.43, and 12.27 cmH(2)O . s . L-1. On five
separate occasions, 15 volunteers exercised to voluntary endpoint on a trea
dmill at fixed speeds and grades chosen to elicit 85% of maximal aerobic ca
pacity for an unencumbered condition. Exercise performance time was recorde
d at the cessation of each test. Results showed that performance time decre
ased linearly (R-2 = 0.79; p <0.001) with increased resistances, and no thr
eshold value below which expiratory resistance has no impact on performance
was found. Average oxygen consumption rates and minute ventilation also de
creased linearly with increased expiratory resistances, indicating that inc
reases in expiratory resistance result in a considerable level of hypoventi
lation. From the perspective of respirator design, the results of this stud
y suggest that the only practical expiratory resistance level limitation is
the reduction in performance that will be acceptable to the end users.