This paper describes the USAF program for controlling potential exposures to hydrazine as it is used on the F-16 aircraft. The evaluation of exposures to hydrazine during various aircraft maintenance activities is described. Cooperation between a defense contractor and the line and medical service of the USAF led to an engineering design concept which emphasizes control of exposure and minimizing the potential of accidental exposure. Recognizing that the risk of an accidental exposure will never be reduced to zero, the USAF Medical Service has implemented a comprehensive program of medical surveillance and health education directed towards the work force responsible for maintenance of the F-16 hydrazine system. The paper has crossover interest to non-toxicologists and non-industrial hygienists; it demonstrates the benefit of consulting the medical community early in the development and acquisition of any new system which involves potential exposure to hazardous materials.