Carbon dioxide (CO2) is widely used across industries, but without proper safety monitoring, it can pose serious health and safety risks. Installing a CO2 safety monitoring system helps businesses comply with OSHA, NFPA, and IFC regulations while protecting employees, customers and facilities from hazardous gas exposure.
This guide explains the top benefits of CO2 gas safety monitoring, best installation practices and key considerations for choosing the right system for your workplace.
Why CO2 Safety Monitoring Is Essential for Compliance and Workplace Safety
Carbon dioxide is a colorless, odorless gas that can accumulate quickly in confined or poorly ventilated areas. High concentrations displace oxygen, causing dizziness, confusion, unconsciousness, and even fatalities. Without continuous monitoring, dangerous CO2 levels can go undetected until symptoms become severe.
This is why industries such as food and beverage, indoor agriculture, laboratories, industrial manufacturing and gas distribution are regulated by strict OSHA, NFPA, and IFC codes that require CO2 monitors be installed near storage or high use areas. CO2 monitoring systems are designed to provide real-time gas detection, triggering audible and visual alarms when levels exceed safety thresholds and allow employees time to evacuate or stop operations safely.
Beyond regulatory compliance, CO2 safety monitoring reduces liability, minimizes costly emergency responses and improves operational efficiency by preventing equipment failures, CO2 waste, and unnecessary shutdowns. Installing a fixed CO2 safety system such as the Remote CO2 Storage Safety 3 Alarm (RAD-0102-6-HS2) ensures continuous protection in basements, storage rooms, and confined workspaces.
Key Benefits of a CO2 Safety Monitoring System
Implementing a CO2 safety monitoring system provides businesses with critical protection, compliance, and operational advantages.
One of the primary benefits is employee and customer safety, as these systems continuously monitor CO2 levels and trigger immediate alerts when dangerous concentrations are detected. This proactive approach helps prevent accidents, exposure-related illnesses, and potential fatalities in confined spaces where CO2 buildup can occur.
Another advantage is cost savings, as early detection of leaks can help businesses avoid expensive CO2 waste, equipment malfunctions, and emergency evacuations.
For businesses requiring multi-gas detection capabilities, the MSC2 Fixed Carbon Dioxide Gas Detector is an ideal solution. This system can monitor 1-3 gases simultaneously, making it highly adaptable for industries such as breweries, food and beverage production, laboratories, and industrial facilities where multiple gases may be present.
Equipped with high-precision sensors and customizable alarm settings, the MSC2 CO2 Gas Detector, ensures continuous gas safety monitoring, helping businesses maintain a safe and compliant working environment while minimizing risks associated with CO2 exposure.
CO2 Safety Monitoring System Installation
CO2 safety monitoring systems are used anywhere compressed CO2 is stored or used indoors. Depending on the application they may be required by state or local jurisdictions.
While mounting the CO2 safety sensor 12 inches from the floor is best for early warning, it makes it difficult to read the CO2 level on the screen. This is why most CO2 safety alarms have 2 parts:
- CO2 Sensor - mounted near the gas 12 inches (32cm) from the floor
- Remote Display - mounted outside the door at 60 inches (152cm).
- CO2 Safety Signs - to warn occupants if a leak occurs.
Note that while both devices include audible and visual alarms, the remote display and safety signs are important because they warn staff before entering an enclosed area with potentially high CO2 levels.
CO2 Sensor Installation
Before installing your CO2 (carbon dioxide) monitoring system, it is important to know that proper device placement is important for full functionality and employee safety.
Careful thought should be put into planning the system placement, electrical wiring, and protection of the devices as well as training employees about what to do if they hear an alarm.
The CO2 sensor should be mounted 12 inches (31cm) from the floor. The CO2 monitoring system display should be mounted 60 inches (152cm) from the floor.
Note: Do not confuse CO2 (carbon dioxide) monitors with CO (carbon monoxide) monitors. Here's how they are different. CO alarms should be mounted in residential or commercial spaces to detect CO gas generated by flames or furnaces. CO alarms should be mounted on the ceiling or near the top of a wall.
A site assessment should consider two additional factors before you install a CO2 safety monitoring system.
- You should understand the local and state codes that may require additions to your CO2 safety monitoring system. High-visibility strobe lights mounted above doors are the most common additions required.
- Some jurisdictions also require CO2 safety monitors be tied to the fire alarm panel to trigger an automatic call to the local fire department to warn of a CO2 leak.
Depending on your local inspector or fire codes, meeting these requirements is not an option. You can be fined if these requirements are not met. Contact us for information about your local codes.
Once you know the approximate location of the sensors, the confined space, and how many you'll require, the next step is to determine how to power them.
While our CO2 safety monitors use 110-220 VAC 50/60 Hz to 12VDC power, a 24 VDC hard-wired power option is available if normal wall power is not readily available or if the user prefers the added benefit of ensuring the device cannot be unplugged. The important thing to remember is that the CO2 sensor should be mounted in such a way that it cannot be accidentally damaged when moving kegs, crates or gas cylinders nearby. In addition, if using the power adapter insure that the plug is secured to the wall so that staff does not accidentally or purposefully unplug the alarm.
Why mount CO2 sensors 12 inches from the floor?
Carbon dioxide gas is heavier than air. If a leak occurs, CO2 will pool on the floor first, then slowly rise.
It helps to think of CO2 gas like water. If your building were flooded, where would the water collect first? That's where CO2 will collect too, and why the CO2 safety monitor sensor should be mounted there.
If you have a basement staircase near a CO2 tank, cylinder or CO2 system manifold, the CO2 gas will flow down the stairs and fill the basement before it will start to fill the main floor. In this case, you should have a safety monitor sensor 12 inches off the basement floor too.
Remote Display Installation
Both the CO2 Sensor unit and remote display unit have audible and visual alarms. However, while the CO2 sensor monitors in an enclosed area where a potential CO2 leak could occur, the remote display is designed to be mounted outside the space and to warn staff of a potential gas leak before entering the area.
Remote displays should be mounted 60 inches (152cm) from the floor and near the door frame of any door entering the enclosed area. They should be mounted on the same side as the door handle to insure they are not covered when the door is open.
Most CO2 safety monitors include the ability to connect two or more remote displays to a single CO2 sensor if there is more than one entry door.
CO2 Safety Signage
Once the CO2 safety sensor and remote display(s) are installed, you should install safety signage at every door. The signage should be visible whether the door is opened or closed.
Note that our CO2 Safety Systems include necessary signage in both English and Spanish. You can download these signs to print here.
Depending on your local codes, you may also be required to have National Fire Prevention Association (NFPA) 704 signs on the outside of your building to warn emergency first responders of stored gases inside your facility. Learn more about NFPA 704 signs for CO2 here.
Bulk CO2 System Area Coverage
In these applications monitors cover approx. 1,500 sq. feet (length x width of the space). Typically, placing the CO2 sensor within 10 feet of the bulk CO2 storage tank, cylinders, and the BIB rack is sufficient. Larger spaces or facilities where these components are separated may require additional monitors. Enclosed rooms or spaces like closets, offices, bathrooms, and keg coolers may require additional monitoring as gas can be trapped in these spaces because of the enclosure.
How CO2 Safety Monitors Support OSHA, NFPA, and IFC Code Compliance
Understanding CO2 safety codes can also be complex, but gas safety monitoring systems make compliance easier and more predictable. OSHA requires employers to maintain safe indoor air quality and ensure workers are not exposed to CO2 concentrations above established permissible limits. CO2 safety alarms also provide a proactive way to remain within OSHA thresholds and document that safety precautions are in place.
NFPA and IFC codes govern the installation of CO2 safety systems used for beverage dispensing, bulk CO2 tanks, and compressed gas storage. Most jurisdictions now require fixed CO2 safety alarms in storage rooms, basements, and areas where CO2 is piped or stored. A properly installed gas safety monitoring system demonstrates compliance during inspections and can prevent costly violations.
Many inspectors also require high-visibility strobes, remote displays outside entry doors, and integration with the building fire panel. A certified CO2 safety system helps meet these requirements while creating a safer environment for employees and emergency responders.
For further information on CO2 safety monitoring, meeting code compliance, or overall installation tips - contact us today.
