When working in an automotive workshop, the risks linked to vehicle exhaust gases should never be underestimated. One of the most dangerous substances is carbon monoxide (CO): a highly toxic gas that is difficult to detect and can cause serious harm to workers if it accumulates indoors.

In this guide, we look at what carbon monoxide is, how it forms, the main symptoms of CO poisoning and the practical safety strategies workshops can adopt to maintain a healthier working environment.

What is carbon monoxide and how does it form?

Carbon monoxide, or CO, is a gas produced by the incomplete combustion of fuels such as petrol, diesel, gas and wood.

Any activity involving internal combustion engines inevitably produces CO, which is released through vehicle exhaust pipes together with other harmful fumes and gases.

The amount of carbon monoxide released depends mainly on the quality of combustion and the condition of the engine. The less efficient the combustion process, the greater the risk. For this reason, workshops should be equipped with properly designed vehicle exhaust extraction systems that capture exhaust gases directly at source.

Why is carbon monoxide so dangerous?

Unlike other combustion by-products, carbon monoxide is odourless, tasteless and invisible. This makes it particularly difficult to recognise its presence in the working environment without appropriate safety measures.

When inhaled, carbon monoxide interferes with the blood’s ability to transport oxygen around the body. This can lead to poisoning that may become dangerous very quickly, especially in enclosed or poorly ventilated spaces.

Symptoms of carbon monoxide poisoning

The symptoms of carbon monoxide poisoning can easily be mistaken for everyday illness, which is why the danger is often not recognised in time. Warning signs may include:

• Sudden or severe headache
• Dizziness or weakness
• Nausea or vomiting
• Breathing difficulties or shortness of breath
• Confusion, disorientation or difficulty concentrating
• Loss of consciousness in severe cases

Prolonged or intense exposure may cause permanent damage to internal organs and the nervous system and, in extreme cases, can be fatal.

How to protect against carbon monoxide in automotive workshops

Prevention is always the most effective strategy. In daily workshop operations, frequent use of internal combustion engines inevitably produces vehicle exhaust gases. These gases are the result of petrol or diesel combustion and release a complex mixture of toxic substances, including carbon monoxide.

Even short exposure to combustion gases may cause symptoms of poisoning. That is why workshops need clear safety strategies to protect the health and wellbeing of technicians and anyone working nearby.

Let's take a closer look at the main steps to take to minimize the risks associated with carbon monoxide:

1. Use professional vehicle exhaust extraction systems

An effective way to prevent the build-up of CO in the workplace is to use professional exhaust gas extraction systems. These systems capture gases directly at source - the vehicle exhaust outlet - before they can disperse into the workshop air.

The right extraction system depends on several factors, including the size of the workshop, the frequency of use, the vehicles handled and the type of exhaust gases produced.
The main solutions available include:

• Fixed systems

  Ideal for workshops carrying out regular maintenance in defined work bays. Exhaust gases are captured directly from the tailpipe using nozzles and flexible hoses, then conveyed outdoors through permanent ducting.
  
  

• Sliding systems

  Equipped with trolleys or hose reels mounted on overhead rails, these systems can reach multiple workstations easily. They provide flexibility and efficiency while keeping the floor area clear, making them suitable for larger workshops or complex layouts.

• Underfloor systems

  The ducting is installed below the floor, with access through floor pits from which hoses and nozzles can be pulled out when needed. These systems are ideal where upper areas need to remain free or where height constraints limit overhead installation.

• Mobile systems

  Wheel-mounted units that can be moved where required and do not need permanent installation. They are a practical solution for small workshops, temporary applications or occasional extraction in different areas.

2. Carry out regular maintenance

Regular maintenance of vehicle engines, machinery and extraction systems is essential to reduce carbon monoxide emissions. A well-maintained engine produces fewer toxic gases and operates more efficiently, helping to create a safer and healthier working environment.

What do workplace safety regulations say?

Workshop safety regulations vary from country to country, but where they apply they set clear requirements for the protection of workers and the management of hazardous fumes and exhaust gases.

In Italy, Legislative Decree 81/08 defines key requirements for air quality management and protection against risks linked to exposure to hazardous fumes and gases. It requires adequate measures to ensure a healthy environment and reduce the risk of harmful substances such as exhaust fumes and combustion gases accumulating indoors.

Complying with applicable safety requirements means protecting workers’ health while also reducing the risk of penalties, legal issues and operational disruption.

What to do in an emergency: first aid for suspected CO poisoning

If carbon monoxide poisoning is suspected in the workshop, immediate action is essential:

• Move the affected person out of the contaminated area immediately.
• Call emergency services without delay and report the possible carbon monoxide exposure.
• Help the person breathe more easily by loosening any tight clothing.
• Do not re-enter the contaminated area until specialist personnel have arrived and the environment has been ventilated and made safe.

Continuous workshop safety starts with prevention

Carbon monoxide is a real risk in automotive workshops, but it can be controlled with the right precautions. Professional exhaust extraction systems and consistent maintenance are essential steps in protecting both workers and the working environment

Workshop safety is a responsibility. A healthier environment improves productivity, reduces hidden costs and protects the people who keep the business running every day.

WORKY designs vehicle exhaust extraction systems for different workshop layouts, vehicle types and operational needs. From fixed and sliding systems to underfloor and mobile solutions, our team helps identify the most suitable configuration for safe, efficient and well-organised workspaces.

FAQ

Why is carbon monoxide dangerous in automotive workshops?

Carbon monoxide is dangerous because it is invisible, odourless and tasteless. When inhaled, it can interfere with oxygen transport in the blood and cause poisoning before workers realise there is a problem.

What is the best way to reduce CO exposure in a workshop?

The most effective approach is to capture exhaust gases directly at source using a properly designed vehicle exhaust extraction system, combined with regular maintenance and safe operating procedures.

Are general ventilation systems enough to protect against carbon monoxide?

General ventilation can help air exchange, but it should not replace local exhaust extraction. Capturing gases at the tailpipe prevents CO and other pollutants from spreading through the workshop.

Which type of exhaust extraction system should a workshop choose?

The choice depends on workshop size, layout, frequency of use, vehicle type and installation constraints. Fixed, sliding, underfloor and mobile systems each respond to different operational needs.

What should be done if CO poisoning is suspected?

Move the person to fresh air immediately, contact emergency services and avoid re-entering the contaminated area until it has been checked and made safe by qualified personnel.