Cold Stress: Protecting Workers in Low-Temperature Environments

Cold stress is a serious hazard that affects workers exposed to cold, wet, and windy environments. When the body loses heat faster than it can produce it, employees can experience fatigue, confusion, and severe injuries such as frostbite or hypothermia.

Employers across industries—from transportation and warehousing to construction and utilities—must understand how to identify, prevent, and manage cold stress to maintain compliance and protect their workforce during winter and low-temperature operations.

Understanding Cold Stress and Its Effects

Cold stress occurs when environmental conditions force the body’s core temperature to drop below normal levels. Factors that contribute include air temperature, humidity, wind speed, and contact with cold surfaces or water.

Common types of cold-related illnesses include:

• Hypothermia: A drop in body temperature that affects brain function, causing confusion, fatigue, and loss of coordination.

• Frostbite: The freezing of skin and tissue, typically affecting fingers, toes, ears, and the nose.

• Trench Foot: Caused by prolonged exposure to cold and wet conditions, even above freezing temperatures.

• Chilblains: Skin inflammation due to repeated exposure to cold air.

The Centers for Disease Control and Prevention (CDC) and the Occupational Safety and Health Administration (OSHA) both recognize cold stress as a preventable but dangerous condition that can result in permanent injury or death if not properly managed.

OSHA Guidance and Employer Responsibilities

Although OSHA does not have a specific cold stress standard, employers are required under the General Duty Clause (Section 5(a)(1)) of the Occupational Safety and Health Act to provide a workplace free from recognized hazards.

This includes taking reasonable steps to protect workers from extreme cold conditions. OSHA recommends that employers:

• Evaluate environmental conditions and exposure duration.

• Provide training on recognizing and preventing cold-related illnesses.

• Supply proper personal protective equipment (PPE).

• Establish procedures for monitoring employees working in cold conditions.

For official OSHA winter weather safety guidance, visit osha.gov/winter-weather.

Who Is Most at Risk?

Cold stress can affect anyone, but workers in the following roles face higher risk:

• Outdoor construction and maintenance crews

• Transportation and delivery personnel

• Utility and telecommunications workers

• Emergency responders

• Warehouse or cold-storage employees

Individual factors also play a role. Workers with inadequate clothing, dehydration, fatigue, or certain medical conditions (such as diabetes or cardiovascular disease) may be more susceptible.

Prevention Strategies

Preventing cold stress starts with preparation and awareness. Employers can protect workers through engineering controls, administrative practices, and appropriate PPE.

Engineering Controls

• Provide heated shelters, break areas, or warming stations.

• Use windbreaks or barriers where possible.

• Ensure adequate insulation in vehicles, trailers, and equipment cabins.

Administrative Practices

• Schedule work during the warmest part of the day.

• Rotate workers between cold and warm environments.

• Implement a buddy system for early symptom recognition.

• Encourage hydration and warm, high-energy meals.

Personal Protective Equipment (PPE)

• Use layered clothing: moisture-wicking base, insulating middle, and waterproof outer layer.

• Provide insulated gloves, socks, and boots.

• Ensure workers have access to dry replacements if clothing becomes wet.

The National Institute for Occupational Safety and Health (NIOSH) provides additional guidance on PPE selection and work/rest recommendations for cold exposure.

Recognizing the Warning Signs

Training workers to identify early symptoms of cold stress is vital to prevention. Warning signs include:

• Shivering or slurred speech

• Numbness or tingling in extremities

• Loss of coordination or confusion

• Pale, hard, or waxy skin

Supervisors should be trained to monitor employees and initiate first aid or emergency procedures immediately if symptoms are observed.

Building a Cold Weather Safety Plan

A comprehensive cold stress program should include:

1. Exposure Assessment: Evaluate temperature, wind chill, and work duration.

2. Training: Educate workers on symptoms, prevention, and response.

3. Communication: Provide weather updates and emergency contacts.

4. Monitoring: Assign trained personnel to observe conditions and worker behavior.

5. Emergency Procedures: Outline steps for first aid, warming, and medical response.

6. Documentation: Maintain records of training and incident responses for compliance and program improvement.

Transportation and Cold-Storage Considerations

For transportation and logistics sectors, cold stress often occurs during loading, unloading, or roadside assistance tasks. Drivers who move between heated cabs and cold outdoor conditions may face rapid temperature shifts that increase risk.

Cold-storage employees, meanwhile, face extended exposure to low-temperature environments. Employers should implement policies for warm-up breaks, specialized PPE, and continuous temperature monitoring inside facilities.

The U.S. Department of Transportation (DOT) also provides guidelines for vehicle maintenance and driver safety in winter weather, helping reduce risks associated with mechanical failure and prolonged exposure.

Fostering a Safety-First Culture

Creating a strong safety culture goes beyond compliance—it requires engagement at every level of the organization. Encourage employees to speak up about unsafe conditions, and make reporting procedures clear and non-punitive.

Regular safety huddles and toolbox talks focused on seasonal hazards help reinforce cold-weather best practices and keep safety top of mind throughout the winter months.

Conclusion

Cold stress remains one of the most overlooked seasonal hazards, yet it’s among the most preventable. By proactively assessing risk, equipping workers with proper clothing and training, and establishing a clear safety plan, organizations can protect employees and maintain productivity during cold-weather operations.

At Sentry Road, we help organizations develop comprehensive safety programs and provide targeted training on topics like cold stress, emergency response, and PPE use—ensuring your team stays safe, compliant, and prepared year-round.