Heat Safety at Work: Prevention and Response Tips
Learn how to prevent and respond to heat illness in the workplace. Get expert tips, OSHA guidance, and tools to protect your team during hot conditions.
Introduction
As temperatures rise each summer, so does the risk of heat-related illnesses on job sites across the country. From construction zones to delivery routes, manufacturing floors to agricultural fields, millions of U.S. workers are exposed to high-heat environments—putting them at risk for heat exhaustion, heat stroke, and other preventable health hazards.
Whether you’re an EHS manager, site supervisor, or operations lead, understanding how to prevent and respond to heat illness is more than a matter of compliance—it’s a matter of protecting your people and keeping your workplace running smoothly.
What Is Heat Illness?
Heat illness is a spectrum of health conditions that occur when the body can’t cool itself effectively. It ranges from mild symptoms like heat rash and cramps to severe and life-threatening conditions such as heat exhaustion and heat stroke.
According to the Occupational Safety and Health Administration (OSHA), thousands of workers fall ill from heat exposure each year—and dozens die. These incidents are largely preventable with the right preparation and response.
Common Types of Heat Illnesses
1. Heat Rash
Often the first warning sign, heat rash appears as red clusters of small blisters, typically in areas where sweat accumulates. While not life-threatening, it’s uncomfortable and may hinder performance.
2. Heat Cramps
Painful muscle spasms, often in the legs or abdomen, are caused by loss of salt through sweating. Cramps may be a precursor to more serious conditions.
3. Heat Exhaustion
Symptoms include dizziness, nausea, heavy sweating, weakness, and rapid heartbeat. Left untreated, heat exhaustion can progress to heat stroke.
4. Heat Stroke (Medical Emergency)
The most severe form of heat illness, heat stroke occurs when the body’s core temperature exceeds 104°F. Symptoms include confusion, loss of consciousness, dry skin, and seizures. This is a medical emergency—911 should be called immediately.
Who’s Most at Risk?
Workers in industries with high heat exposure are particularly vulnerable. These include:
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Construction
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Agriculture
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Transportation and warehousing
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Manufacturing
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Oil and gas
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Landscaping
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Waste management
Certain groups also face elevated risk: new workers, older adults, people with chronic health conditions, and those who wear heavy PPE.
The Centers for Disease Control and Prevention (CDC) notes that acclimatization—or gradually increasing exposure to heat—is a critical step in prevention, especially for new or returning workers.
Key Components of a Heat Illness Prevention Plan
1. Access to Water, Rest, and Shade
Encourage frequent water breaks, even when workers aren’t thirsty. OSHA recommends one cup (8 oz.) of water every 15–20 minutes. Rotate workers through shaded or air-conditioned areas, and increase break frequency during high-heat conditions.
2. Heat Acclimatization Programs
Implement phased work schedules for new employees or those returning after extended absences. A gradual increase in workload over 7–14 days helps the body adapt.
3. Training and Awareness
Supervisors and workers should be trained to recognize early symptoms and know how to respond. OSHA’s Heat Illness Prevention Training Guide offers free resources and multilingual materials.
4. Monitoring Environmental Conditions
Use Wet Bulb Globe Temperature (WBGT) monitors or consult local weather forecasts. High humidity can drastically increase heat risk, even when the air temperature is moderate.
5. Emergency Response Protocols
Clear, practiced protocols are vital. Make sure your team knows:
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How to identify symptoms
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When to move a worker to a cooler location
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When to call 911
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How to perform first aid (e.g., applying cool compresses, removing outer clothing)
Best Practices by Industry
Construction & Roofing
Rotate tasks to avoid long exposure, ensure PPE doesn’t trap heat unnecessarily, and use cooling vests when possible.
Warehousing & Logistics
Install fans or HVAC systems where feasible, limit time in trailers or poorly ventilated spaces, and schedule physically demanding tasks during cooler hours.
Transportation & Trucking
Drivers face added risk due to cab conditions and loading/unloading in the sun. FMCSA emphasizes driver wellness and hydration.
Agriculture & Landscaping
Use portable shade structures, provide electrolyte-replenishing beverages, and encourage team leads to monitor each other for symptoms.
Regulatory Considerations
OSHA Guidance
While there is no federal OSHA standard specific to heat, the General Duty Clause requires employers to provide a workplace free from recognized hazards—including heat stress. Several states, such as California and Washington, have their own heat illness prevention standards.
DOT/FMCSA Guidelines
While the FMCSA doesn’t have heat-specific regulations, it does require motor carriers to protect drivers’ health and prevent unsafe operating conditions, which may be exacerbated by high heat.
Leveraging Technology
Consider using digital tools to:
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Push heat advisories to teams based on location
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Track worker acclimatization
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Automate break reminders
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Monitor conditions with smart sensors
These approaches not only improve compliance but help organizations respond proactively to changing weather conditions.
Final Thoughts
Heat illness is one of the most preventable workplace health threats—yet it's one of the most persistent. By integrating awareness, planning, and responsive action, employers can reduce risks, avoid downtime, and support a safer, more resilient workforce.
Looking for support on Heat Illness Prevention and Response?
Sentry Road helps organizations build smarter safety programs—from seasonal heat awareness to year-round compliance. Contact us to learn how we can support your team.