Strong inorganic acid mists containing sulfuric acid were identified as a 'known human carcinogen' in a National Toxicology Program (NTP) report where phosphate fertilizer manufacture was listed as one of many occupational exposures to strong acids. To properly assess the occupational exposure to sulfuric acid mists in modern facilities, approved National Institute for Occupational Safety and Health (NIOSH) Method 7903 and a cascade impactor were used for measuring the total sulfuric acid mist concentration and size-resolved sulfuric acid mist concentration, respectively. Sampling was conducted at eight phosphate fertilizer plants and two background sites in Florida and there were 24 sampling sites in these plants. Samples were analyzed by ion chromatography (IC) to quantify the water-soluble ion species. The highest sulfuric acid concentrations by the cascade impactor were obtained at the sulfuric acid pump tank area. When high aerosol mass concentrations (100 micro g m(-3)) were observed at this area, the sulfuric acid mists were in the coarse mode. The geometric mean sulfuric acid concentrations (+/-geometric standard deviation) of PM(23) (aerodynamic cut size smaller than 23 micro m), PM(10) and PM(2.5) from the cascade impactor were 41.7 (+/-5.5), 37.9 (+/-5.8) and 22.1 (+/-4.5) micro g m(-3), respectively. The geometric mean (+/-geometric standard deviation) for total sulfuric acid concentration from the NIOSH method samples was 143 (+/-5.08) micro g m(-3). Sulfuric acid mist concentrations varied significantly among the plants and even at the same location. The measurements by the NIOSH method were 1.5-229 times higher than those by the cascade impactor. Moreover, using the NIOSH method, the sulfuric acid concentrations measured at the lower flow rate (0.30 Lpm) were higher than those at the higher flow rate (0.45 Lpm). One possible reason for the significant differences between the results from the cascade impactor and the NIOSH method is the potential artifact resulting from the interaction of SO(2) with silica gel and glass fiber used in the NIOSH method.