How to Prevent Cold Burns When Using a CO₂ Fire Extinguisher

Carbon dioxide (CO₂) fire extinguishers are some of the most common extinguishers you’ll find in workplaces—especially around electrical equipment, server rooms, laboratories, workshops, fueling areas, and industrial environments. They are fast, effective, and leave no residue.

But they also come with a serious hazard many workers underestimate: cold burns (frostbite).

When discharged, a CO₂ extinguisher releases gas at extremely low temperatures — sometimes as low as -78°C (-108°F). This rapid temperature drop can instantly freeze skin, causing painful cold burns. These burns are not only common; they’re 100% preventable with the right knowledge and practical technique.

This guide focuses on exactly that—how to prevent cold burns when using a CO₂ extinguisher in a workplace setting. No fluff, no irrelevant theory; just practical, experience-backed safety guidance.

What Causes Cold Burns When Using a CO₂ Fire Extinguisher?

Cold burns occur because carbon dioxide expands rapidly when discharged, turning from liquid to gas. This process—called adiabatic expansion—forces the CO₂ to release at freezing temperatures.

When workers accidentally touch the horn, metal nozzle, or discharge pipe, the skin can stick to the frozen surface and burn instantly.

Common mistakes that cause cold burns include:

• Holding the horn directly (especially on non-insulated horns)

• Resting fingers near the nozzle while squeezing the trigger

• Wearing thin gloves that do not provide thermal protection

• Allowing the CO₂ discharge plume to contact exposed skin

• Holding the extinguisher improperly due to panic or lack of training

Cold burns from CO₂ extinguishers are workplace injuries that often go unreported, but they are preventable with simple safety habits.

Read Also: Safety Measures Used After a Large Lithium Battery Catches Fire

How to Prevent Cold Burns When Using a CO₂ Fire Extinguisher

Below are practical, step-by-step, workplace-ready safety actions to prevent cold burns. These are field-tested practices used across industries such as construction, manufacturing, oil & gas, laboratories, and office environments.

1. Only Use the CO₂ Fire Extinguisher by the Handle and Insulated Grip

Every CO₂ extinguisher is built with a handle, lever, and insulated horn grip. These parts are safe to hold even when the extinguisher becomes extremely cold.

To prevent cold burns:

• Hold the extinguisher by the top handle (the carrying handle)

• Use the discharge handle/lever to operate

• Position your support hand only on the insulated horn handle, never on the horn itself

If the extinguisher has no insulated grip, it must not be used without hand protection.

2. Never Touch the Horn or Metal Nozzle During or After Discharge

Once CO₂ is discharged, the horn can instantly drop to freezing temperatures and remain extremely cold for minutes.

Touching the horn — even accidentally — is the number one cause of frostbite injuries in workplaces.

Practical safety tips:

• Keep fingers completely away from the horn area

• Do not attempt to adjust or reposition the horn

• Do not attempt to remove ice buildup from the nozzle or horn

• Treat everything beyond the handle/trigger area as a “NO-TOUCH ZONE”

Even insulated horns can get partially cold if the insulation is damaged.

3. Always Check for an Insulated Horn Before Use

CO₂ extinguishers come in two designs:

1. Insulated horn (safer; includes a black plastic handle)

2. Non-insulated horn (older models; very dangerous for untrained users)

Before you ever use a CO₂ extinguisher, quickly check:

• Is the horn insulated?

• Is the insulation cracked or missing?

• Is the handle secure and intact?

If the horn insulation is damaged, tag the extinguisher out-of-service and report it immediately.

In many workplaces, employees have suffered burns simply because they grabbed the extinguisher closest to them without checking its condition.

4. Wear Hand Protection in High-Risk Environments

While most workers will not be wearing thermal gloves during an emergency, some environments require or recommend gloves when fighting fires involving CO₂.

These include:

• Laboratories

• Workshops

• Industrial plants

• Battery storage areas

• Electrical maintenance rooms

Thermal or leather gloves can reduce the risk of cold burns, especially when:

• The horn insulation is questionable

• The extinguisher is older

• The user is inexperienced

• Work environment is cold and the risk of finger numbness is high

Gloves should not replace training—they simply add a layer of protection.

5. Maintain a Firm, Controlled Grip

Many cold burns happen because workers panic during a fire and place their hands in unsafe locations. A stable grip ensures your hands stay exactly where they should be.

Use this technique:

• Dominant hand on the handle/trigger

• Non-dominant hand on the insulated horn handle

• Keep elbows slightly bent

• Aim the discharge horn at the base of the fire

If the extinguisher recoils slightly, your hands will remain in the correct safe zones.

6. Stand Upwind and Keep the CO₂ Discharge Away from Skin

The CO₂ jet is extremely cold. If it blows back onto your face, arms, or hands, it can cause cold burns or frostbite.

To prevent this:

• Stand upwind if outdoors

• Ensure adequate ventilation indoors

• Keep your arm extended and away from the direction of the nozzle

• Maintain at least 1 meter (3 ft) distance from the fire

The further CO₂ travels before reaching your skin, the warmer it becomes.

7. Follow the PASS Technique Correctly

The PASS method keeps your hands where they should be—on the insulated and safe parts of the extinguisher.

P – Pull the pin
Hold the handle only.

A – Aim the nozzle
Use only the insulated handle to aim. Never touch the horn.

S – Squeeze the lever
Use your dominant hand; keep the other hand on the insulation.

S – Sweep from side to side
Keep sweeping until the fire is out or the CO₂ runs out.

Proper technique automatically prevents burns by keeping your hands away from hazardous components.

8. Receive Hands-On Fire Extinguisher Training (Mandatory for Employees)

Lack of training is the biggest root cause of cold-burn injuries.

Every workplace should provide:

• Practical fire extinguisher handling demonstrations

• Hands-on discharge practice (with training units)

• Clear explanation of cold-burn hazards

• Visual examples of safe vs. unsafe holding points

A worker who has never used a CO₂ extinguisher physically is more likely to grab it incorrectly in a real emergency.

Hands-on training builds muscle memory.

9. Keep the Extinguisher in Good Condition

Poorly maintained CO₂ extinguishers are more likely to cause burns because:

• Insulation gets cracked

• Nozzles become loose

• Horns wobble and require repositioning (unsafe)

• Ice buildup occurs more quickly

Routine maintenance should include:

• Annual servicing by a certified technician

• Checking insulation integrity

• Ensuring horn and nozzle are tightly fitted

• Confirming discharge pathway is not blocked

• Removing expired or damaged units

A damaged extinguisher is a workplace hazard and must be replaced or repaired immediately.

10. Do Not Use a CO₂ Fire Extinguisher for Training Without Gloves

During training, the extinguisher is handled repeatedly, often by multiple people. This increases the chances of accidental horn contact, especially in cold weather.

Trainers should:

• Provide gloves

• Demonstrate the NO-TOUCH ZONE

• Supervise users closely

• Allow only insulated models for practice

Proper training practices dramatically reduce accidental burns.

Read Also: How to Become a Fire Protection Engineer in the U.S.

11. Never Attempt to Clean or Scrape Ice Off the Horn

When CO₂ is discharged, ice crystals may form around the horn. Some employees instinctively try to wipe the ice off because they think it’s blocking flow.

This is extremely dangerous.

To stay safe:

• Leave the ice alone; it is normal

• Do not wipe, scrape, or tap the horn

• Allow the extinguisher to warm naturally afterward

Touching frozen components is one of the fastest ways to get a cold burn.

12. Keep Bare Skin Covered During Discharge

If your workplace requires the use of short-sleeved shirts, be mindful that exposed skin is more vulnerable to CO₂ frost.

Best practice:

• Keep your arms extended

• Maintain safe distance

• Do not rest your arm against the horn or cylinder

• Avoid leaning too close to the discharge plume

A safe body position equals safer skin.

13. Never Reposition the Horn While the Extinguisher Is Discharging

Some workers try to adjust the horn angle mid-operation. This is how cold burns happen instantly.

If you need to change direction:

• Release the handle

• Allow discharge to stop

• Reposition using the insulated grip

• Resume discharging

This simple habit prevents accidental contact with frozen surfaces.

What To Do If Someone Suffers a Cold Burn

Even with all precautions, accidents can still occur. Quick first aid can reduce injury severity.

First Aid for Cold Burns (Frostbite):

• Remove the person from the cold area immediately

• Do not rub or massage the burned area

• Soak the affected area in lukewarm (not hot) water for 20–30 minutes

• Loosely bandage the skin with sterile gauze

• Avoid applying direct heat

• Seek medical attention if:

  • The skin is pale or white

  • Blisters form

  • There is severe pain

  • Sensation is reduced

Report the incident as per workplace injury protocols.

Why CO₂ Extinguishers Are Still Safe When Used Correctly

Many workers believe CO₂ extinguishers are dangerous because of the cold burn risk, but the truth is simple:

CO₂ extinguishers are safe when used correctly, with proper hand placement and training.

You only get burned when:

• You touch the horn

• You hold the extinguisher improperly

• You ignore the insulated handle

• You haven’t been trained

This makes training the single most important safety control.

Conclusion: Cold Burns Are 100% Preventable With the Right Techniques

Cold burns from CO₂ extinguishers are completely avoidable. With proper training, safe grip positioning, awareness of the NO-TOUCH ZONE, and good workplace practices, any worker can operate a CO₂ extinguisher confidently without injury.

To summarize the key prevention steps:

• Use only the handle and insulated grip

• Never touch the horn or nozzle

• Check for insulation before use

• Wear gloves in high-risk environments

• Maintain stable grip and distance

• Follow the PASS technique

• Keep extinguishers properly maintained

• Avoid touching ice buildup

• Get hands-on training regularly

Read Also: Who Should be Trained on the Contents of an Emergency Action Plan?

When employees understand these steps, they can extinguish fires safely and effectively—without risking frostbite.

A CO₂ extinguisher is a powerful tool. With the right knowledge, it stays a safe one too.