Explore the threat of carbon monoxide poisoning in the workplace, which industries are at the highest risk, and what solutions can help prevent this dangerous hazard.
Carbon monoxide (CO) poisoning is a workplace hazard that occurs when you inhale too much carbon monoxide. This colorless and odorless gas is often produced by burning fuel in vehicles, stoves, lanterns, grills, fireplaces, gas ranges, or furnaces. Because it is invisible and lacks an odor, it can accumulate indoors without being detected.
CO differs from carbon dioxide (CO₂), a gas naturally present in the atmosphere and essential for life. CO₂ is naturally present in the atmosphere and is generally non-toxic at low levels, whereas CO is highly toxic and poses immediate health risks when inhaled.
When inhaled, CO binds with hemoglobin to form carboxyhemoglobin, which reduces the blood’s ability to carry oxygen. As CO levels increase in the bloodstream, tissues and organs become oxygen-deprived. This makes it a workplace hazard that can lead to severe health complications and may even be fatal.
CO poisoning in workplaces can come from various sources:
Areas that lack proper monitoring systems are particularly vulnerable to carbon monoxide buildup. This is especially true for workplaces that have the following:
Fuel-Burning Appliances : Gas stoves, dryers, water heaters, and furnaces release CO into the air through incomplete combustion.
Vehicles and Engines: Vehicles, machinery, and equipment powered by gasoline or diesel engines emit carbon monoxide fumes that can quickly accumulate in enclosed spaces.
Vehicle Exhaust : Indoor parking garages or tunnels where vehicle exhaust is not adequately ventilated are high-risk areas for CO buildup.
This is common in basements, garages, and other confined areas without proper ventilation. CO can accumulate in these spaces, especially when fuel-burning appliances or vehicles run. For example, if a truck or forklift is left running in an enclosed loading dock or a repair shop with inadequate ventilation.
Industries at high risk for CO poisoning include the following:
Manufacturing, especially Chemical Manufacturing
Construction and Welding
CO poisoning can have serious health effects on workers exposed to high levels of the gas. Some of the most common effects on health are the following:
Headaches, dizziness, weakness, confusion, chest pain, nausea, seizures, and vomiting.
P ermanent neurological damage or other chronic health conditions, such as:
cognitive impairment;
cardiovascular damage; and
Delayed Post-Hypoxic Leukoencephalopathy (DPHL).
Broader public safety implications for the following:
Infants
Unborn babies
Children
Pregnant women
Older adults
People with chronic heart disease
People with breathing problems
Aside from health concerns, CO exposure can lead to lower productivity and increased absenteeism in the workplace. Symptoms of CO poisoning can impair an employee’s ability to work efficiently and safely. Worse, it can even cause loss of consciousness or death.
To prevent CO poisoning in the workplace, employers must implement strict safety precautions that include the following:
First and foremost, employers should ensure that all fuel-burning appliances, vehicles, and engines undergo regular maintenance checks. Regular inspections and servicing help detect potential issues, such as leaks or malfunctions, that could lead to hazardous CO emissions.
Another preventative measure is the installation of carbon monoxide detectors in high-risk areas. These devices provide early warnings of CO presence, allowing for timely action before levels become dangerous. Detectors should be installed in critical areas such as near sleeping quarters, kitchens, and garages and regularly tested to ensure they function.
All measures can only be helpful if employees know the risks of CO poisoning or are trained on what to do in an emergency. Employers should conduct regular training programs to educate employees on identifying the signs of CO poisoning, operating equipment safely, and taking steps to take in case of a leak or emergency.
When CO leaks cannot be prevented, having an emergency preparedness plan will ensure that employees are well-equipped. Conducting safety audits can help identify vulnerabilities and improve response strategies. These should include clear instructions on evacuation procedures, communication protocols, and first-aid measures.
Since CO can be hazardous, safety standards and regulations are in place to protect workers, such as:
Occupational Safety and Health Administration (OSHA) Guidelines: There is a set carbon monoxide exposure limit at 50 parts per million over an 8-hour workday. A recent update suggests a stricter limit of 35 ppm as an 8-hour average and a 200 ppm ceiling for short-term exposures (5 minutes).
International Building Code (IBC): The IBC includes CO detection provisions in Section 915 for healthcare, educational, and residential buildings with fuel-burning appliances. It is aligned with NFPA codes, especially NFPA 101, which has similar CO detection requirements for various occupancies.
National Fire Protection Association (NFPA) Codes: NFPA Codes are primarily used in the US, but they are also recognized in other countries as a standard for fire safety and prevention. Specifically, NFPA 720 was the standard for installing CO detection and warning equipment.
In the US, some states may also have their specific regulations for CO monitoring and detection, such as:
New York: Section 1228.4 of Title 19 New York Codes, Rules, and Regulations (NYCRR) outlines the requirements for carbon monoxide detection in commercial buildings.
Illinois : Requires CO detectors for all residential owners, landlords, and building owners.
California : Mandates CO detectors in all new constructions and certain public buildings, outlined in Section 915 of the California Building Code
Other states like Connecticut, Maryland, and Maine also have specific requirements for schools and daycare centers.
Environmental or air quality monitoring systems can help continuously measure CO levels in the workplace. Some advanced systems include:
Carbon Monoxide Sensors: This sensor is specifically designed for customers who need to monitor carbon monoxide levels.
Gateways (IoT): These can be used to connect CO sensors to a network, allowing for remote monitoring and data collection
Internet-of-Things (IoT) Controllers : These facilitate communication between CO sensors and other devices.
Since CO monitoring is an essential aspect of safety mitigation, here’s a step-by-step guide to help workplace safety managers:
Assess Risk Areas: Begin by identifying areas within your workplace where CO could potentially build up, such as places where fuel-burning and engines are involved, enclosed areas with limited ventilation.
Select Appropriate Monitoring Equipment: Choose CO sensors suitable for your specific environment and needs. Consider integrating your sensors with Gateways (IoT) for real-time data access and IoT Controllers for better system integration.
Install Detectors: Install CO detectors in key areas identified in the risk assessment, such as near appliances, enclosed workspaces, and employee rest areas. Ensure they are at the right height and location for best results, as CO is slightly lighter than air and spreads quickly.
Set Up a Maintenance Schedule: Create a regular maintenance routine for CO detectors and monitoring systems. This includes testing, changing batteries, and calibration checks to ensure they work correctly.
Train Employees on CO Monitoring: Provide employees with training sessions to educate them on the risks of CO, how to recognize symptoms of poisoning, and the proper use of monitoring equipment. Training should also cover emergency procedures, such as evacuation routes and first-aid measures.
Utilize Advanced Technologies: Use digital tools to gather, analyze, and share data from CO sensors in real time to ensure workplace safety and that emergency response plans are followed. These technologies can also help with predictive maintenance and make compliance reporting easier.
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