Carbon Monoxide (CO) Exposure Plan
Written CO exposure plan for workplaces with indoor combustion engine operation, kilns and furnaces, garages and parking structures, indoor ice rinks, and other CO-generating operations. OSHA PEL 50 ppm TWA; NIOSH REL 35 ppm TWA. Includes monitoring, alarm response, and training.
When this template is required
Required wherever carbon monoxide exposure may occur — indoor combustion engine operation (forklifts, generators, vehicles in enclosed spaces), confined space welding/cutting, kilns and furnaces, garages and parking structures, indoor ice rinks (Zamboni machines), space heaters, anywhere fuel combustion happens with inadequate ventilation. OSHA PEL 50 ppm TWA.
Why this template
Common but often unrecognised hazard
CO is colorless, odorless, and produces symptoms (headache, dizziness, nausea) easily mistaken for other causes. Many CO exposure incidents are not immediately recognized. Routine monitoring and worker training are essential.
Indoor combustion engine focus
Propane forklift exhaust is the most common workplace CO exposure scenario — indoor LP forklifts can produce significant CO if poorly tuned or with degraded catalytic converter. Periodic engine emission tuning is essential.
Personal and fixed monitoring
Personal CO monitors are standard for high-exposure workers. Fixed monitors with alarms protect larger areas. The plan addresses both.
Ice rink and garage applications
Indoor ice rinks (Zamboni) and parking garages have well-documented CO incidents. The plan addresses these specific high-risk applications.
What you receive
- CO Exposure Plan (Word .docx)
- CO hazard assessment by work area
- Fixed CO monitor and personal monitor program
- Alarm setpoints and response procedures
- Ventilation requirements (engineering controls)
- Indoor combustion equipment maintenance schedule (engine tuning, emission control)
- Employee training outline (CO symptoms, response)
- Emergency response procedure
- Carbon monoxide exposure incident report form
How you get it
This document is written and reviewed against the standard it cites, and it is ready now. The download link is emailed as soon as your payment clears.
Revisions included — if something about your operation changes what the document should say, reply to the delivery email and we will amend it.
Who buys this
- Warehouses with propane / diesel forklifts
- Auto dealers and auto repair shops
- Indoor ice rinks (Zamboni / ice resurfacer operations)
- Construction sites with indoor generator or pressure washer use
- Foundries, kilns, and other thermal operations
- Parking garages and tunnels
- Restaurants with combustion appliances
Frequently asked
What's the OSHA CO PEL?
OSHA 1910.1000 Table Z-1: 50 ppm 8-hour TWA. NIOSH REL: 35 ppm TWA, 200 ppm Ceiling. ACGIH TLV: 25 ppm TWA. The OSHA PEL dates from 1971 and sits well above the NIOSH and ACGIH values, which are consensus recommendations and not enforceable by federal OSHA unless a state plan has adopted them. The plan supports both the federal limit and the lower recommended values.
What's COHb and why does it matter?
Carboxyhemoglobin — the chemical form of hemoglobin bound with CO instead of oxygen. Normal background: 1-2% COHb. 10% COHb = mild symptoms (headache). 30% COHb = severe symptoms (impaired judgment, nausea, dizziness). 50%+ COHb = loss of consciousness, possible death. COHb measurement is the diagnostic test for CO exposure.
How do propane forklifts cause CO exposure?
Propane (LP) forklifts burn fuel inefficiently when poorly tuned or with degraded catalytic converters. Indoor operation in inadequately ventilated warehouses can produce CO levels in the 25-100 ppm range at worker breathing zone. Periodic engine emission tuning (every 200-500 hours) and catalytic converter inspection prevent the buildup. The plan includes the maintenance schedule.
What about indoor ice rinks?
Ice resurfacers (Zambonis and equivalents) running propane or gasoline engines on the ice surface have caused well-documented mass CO exposure incidents at hockey rinks. Players, coaches, and spectators have been hospitalised. The plan addresses ice rink operations specifically — engine maintenance, ventilation, monitoring, and electric resurfacer transition where possible.
What's the emergency response if CO alarm sounds?
Evacuate the area immediately. Don't stop to investigate. Once outside, account for personnel. Don't re-enter until atmospheric measurement confirms safe levels. Anyone with symptoms (headache, nausea, dizziness) should receive medical evaluation with COHb measurement. The plan documents the response procedure.