New Project: Making masks for WGD

As Bogie and I have mentioned in comments one to another, WonderfulGrandDaughter (WGD) has asked me to make some general duty face masks for her staff of nurses and other workers in a facility populated mostly by old and old, old people (I should be there!) Obviously, those workers are affected by the shortage of personal protective equipment.

I cautioned WGD that as an old, old person, my aches and pains will prevent me from doing mass production work; I could make a few, at least. This evening, after settling upon an acceptable design (such as was suggested by WGD and found here or, the one I actually used that was published by Deaconess Hospital in Indiana) I made the first mask. It isn't a beauty; but, I had limitations. The front of the mask is to be made of tightly woven 100% cotton fabric; but, they wish to have something soft against the face of the wearer, such as 100% cotton flannel. The only flannel that I have on hand, that I know is 100% cotton, is yardage that I bought 12 years ago to rebind a comforter that Mom made (in about 1965-1975) for Hunky Husband. With that limitation, I chose a rather masculine-looking (what does that mean???) quilt fabric for the front. Below is a photo collage with the result. I'm sorta thinking that it won't look all that bad on a male staffer. The "front" is shown at the top of the collage. The pine cones are on the flannel.

Can you guess what took me the longest in the process? Well...first, I had to change from the rounded-point sewing machine needle that is used for knits (I had just started making myself a nightgown when I received the request from WGD) to a heavier weight, sharp-point sewing machine needle for heavier weight woven fabrics. I use a small screwdriver to loosen/tighten the set screw that holds the needle in place. I shook so much (essential tremors) that it was difficult for me to achieve the needle change.

Then...there was making the tucks in the mask and sewing through several layers of fabric to keep them in place at the sides. I'm hoping that WGD finds that the mask isn't too thick for someone to breathe through. There are about four or five versions of this design that I want to make as prototypes for WGD so that she can tell me what works and what doesn't before I get too wound up. Last night I cut out fronts from a lilac-colored Paisley quilt fabric; but, I'm trying to find something lighter than the flannel for the back side. On one of the websites, someone suggested using pillowcase fabric for the backing - soft, 100% cotton. If I have an old pillowcase that still sports a fabric content label that says 100% cotton, I'll try that. I'm trying to stick with fabrics that I have on hand rather than going into a retail establishment to buy pieces and parts.

ADDITION of 3/23/2020 - Noon - A bit of info concerning masks and respirators

Your Source of Innovation in the Medical Field

Which Masks Actually Protect Against Coronavirus?

(Credit: Photo Athit Perawongmetha/Reuters)

by Celia Sampol

February 28, 2020 Updated on March 5, 2020

The world is facing a shortage of masks and other protective equipment against the new coronavirus, the head of the World Health Organization warned on Friday, February 7th. Surgical masks are especially in demand. But are they really effective? What kind of masks actually protect against Covid-19? Read this article to find out.

(Our in-house expert Hicham Dhouibi contributed to this article.)

Kolmi-Hopen is one of the major manufacturers of single-use medical products. Under normal circumstances, their facility in France makes 150 million surgical masks and over 20 million respirators per year. Today, with the rising demand, they have been requested to make over 500 million masks altogether. This is what Gérald Heuliez, managing director of Kolmi-Hopen, told French news agency AFP. In the meantime, companies like Foxconn have said they would make 20 million masks by the end of this month to face the world demand.

Since the outbreak, people in China and in the rest of the world have rushed to their local pharmacies to get surgical masks. But there are different types of masks on the market, and not all of them are really effective against this virus. So, which masks actually offer protection? 

See our buying guide on How to choose a surgical mask or a respirator.

Surgical Masks vs. Respirators

There are two different types of masks: surgical masks and respirators.

Surgical mask (Credit: DACH Schutzbekleidung)

 >>> A surgical mask is a disposable medical device that can be bought in pharmacy and that protects against infectious agents transmitted by “droplets.” These droplets can be droplets of saliva or secretions from the upper respiratory tract when the wearer exhales.

If worn by the caregiver, the surgical mask protects the patient and his or her environment (air, surfaces, equipment, surgical site). If worn by a contagious patient, it prevents the patient from contaminating his or her surroundings and environment. These masks should not be worn for more than 3 to 8 hours.

A surgical mask can also protect the wearer from the risk of splashes of biological fluids. In this case, the surgical mask must have a waterproof layer. It can also be equipped with a visor to protect the eyes.

But a surgical mask does not protect against “airborne” infectious agents so it will not prevent the wearer from being potentially contaminated by a virus such as the coronavirus.

 

N95 respirator (Credit: 3M)

 >>> A respirator is personal protective equipment that prevents the wearer from inhaling aerosols (dust, smoke, mist) as well as vapors or gases (disinfectants, anesthetic gases) that are health hazards. Unavailable in pharmacy, it protects the wearer from airborne infectious agents i.e. against contamination by a virus such as coronavirus, SARS, H1N1, etc.

Respirators are divided into two categories: insulating and filtering. Filtering respirators consist of a facepiece and a filtering device. Sometimes the filter element is integrated into the facepiece. Depending on the type of filter, the mask will either be effective only against particles, only against certain gases and vapors, or against particles, gases and vapors.

Filtering respirators can sometimes also be equipped with an exhalation valve to improve user comfort. The valve prevents condensation inside the mask, misting on the glasses and helps the user breathe in and out easily.

It should be noted that respirators also protect those who wear them from inhaling “droplets” of infectious agents. Respirators can be disposable or reusable. In the second case, it is possible to replace the filter when it is full.

What Are the Standards ?

Each of these two types of masks is subject to different standards and regulations depending on the country or geographical area.

>>> Surgical masks are tested in the direction of exhalation (from inside to outside). The tests take into account the efficiency of bacterial filtration.

In Europe, they must comply with the European standard EN 14683, which has 3 levels of bacterial filtration efficiency (BFE1, BFE2, Type R). In the United States, they must respect ASTM standards which have three levels of protection (from low risk of exposure to fluids to high risk of exposure to fluids).

>>> Respirators are tested in the direction of inspiration (from outside to inside). The tests take into account the efficiency of the filter and leakage to the face.

In Europe, they must meet the European standard EN 149: 2001 which has three classes of disposable particulate respirators (FFP1, FFP2 and FFP3).

• • FFP1 refers to the least filtering of the three masks with an aerosol filtration of at least 80% and leakage to the inside of maximum 22%. This mask is mainly used as a dust mask (home renovations and various types of work).
  • FFP2 masks have a minimum of 94% filtration percentage and maximum 8% leakage to the inside. They are mainly used in construction, agriculture, and by healthcare professionals against influenza viruses. They are currently used for protection against the coronavirus.
  • FFP3 masks are the most filtering mask of the FFPs. With a minimum filtration percentage of 99% and maximum 2% leakage to the inside, they protect against very fine particles such as asbestos.

ANOTHER INTERESTING WEBSITE: Can DIY Masks Protect Us from Coronavirus?

The short answer is, "No, but DIY masks are better than nothing."

Comments

[Ole Phat Stu]

I doubt whether that's up to FFP2 standard (filters at least 94% of airborne particles), but it's certainly more cosmetically attractive :-)

[Cop Car]

Stu--My thought, exactly. However, as it turns out, WGD wants masks for general duty around residents who are not suspected of having been exposed to COVID-19.

These masks are not intended to serve in place of N95 masks, but their use can free up available N95 masks for use by those who need them - until N95 masks are more abundantly available. (There are tons of people out there who never before wore a mask in their lives, but now think they must hoard N95 masks!)

I did read up on the effectiveness of different mask configurations using different materials before settling upon Deaconess Hospital's design. At least people won't be spraying sputum over the residents, nor will the residents be spraying them, while wearing such masks.