Author: Heat Aware

Heat Stress Hazards and Effective Control Measures for Workplaces

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Heat stress hazards can be minimized in the workplace with the right control measures, including:

  • Installing safety signage
  • Providing workers with temperature-taking tools
  • Scheduling work rotations to prioritize safety
  • Ensuring there is adequate water and cooling stations available
  • Creating a heat-specific emergency action plan
  • Training workers to recognize the signs of heat illness

According to the Bureau of Labor Statistics, there are more than 3,300 heat illnesses and injuries every year that cause missed work time – and more than 30 workers die every year due to the heat. That’s a lot of lost productivity and potential liability for employers, and tragedy for workers.

Integrating the above practices on the jobsite will greatly improve heat safety in most workplaces. Here is a closer look at each of the preventative measures listed above and how implementing them can make a difference.

1) Installing Safety Signage

Occupational safety signage is a vital first layer of defense for hazardous workplaces, as it offers several advantages. For heat specifically, the fixed version is a heat stress sign that posts the day’s temperature and humidity where the crew stops to drink. Signage can be installed wherever the hazards are and can communicate in multiple languages, making it a cost effective and durable way to keep safety in the forefront of everyone’s minds.

Safety signage reminds workers to stay alert to the signs of heat illness. Signs remind workers to take in enough water and points out where cooling stations are located, and it reminds workers what to do in the event of an emergency.

Given its importance in heat safety and cost efficiency, safety signage is considered a must-have protective measure for any workplace that features heat hazards.

2) Providing Workers with Temperature-Tracking Tools

The first step in preventing heat illness is vigilance, and that means tracking the temperature as it changes throughout the day. This is something that workers can – and should – be trusted with. If workers in the field are most at risk of heat illness, it makes sense that they should have advance notice of potentially unsafe conditions.

An increasingly popular tool for employers is to equip their workers with easy-to-use, reliable liquid crystal thermometers (LCTs). LCTs are lightweight and compact enough that they can be integrated into TWIC cards. They provide a reliable temperature reading within seconds, so workers can respond and take appropriate safety measures as the heat reaches dangerous levels.

3) Scheduling Work Rotations to Prioritize Safety

If your organization can manage it, scheduling work rotations with heat hazards in mind can also reduce risk. This is especially important for new workers who may not be acclimated to elevated temperatures. It is highly recommended that new hires have a chance to slowly acclimate to full work intensity – including slowly ramping up exposure to elevated heat levels.

However, even experienced workers need additional breaks when heat hazards are present. When the forecast calls for hot weather, supervisors can be proactive in scheduling heat-safe work rotations, including shorter rotations or rotations that include less manual labor.

4) Ensuring There is Adequate Water and Cooling Areas Available

An essential control measure for hazardous workplaces is organizing cooling stations. These don’t have to be elaborate setups as some shade, a cooling fan and cold water is all that’s necessary. Ideally, these cooling stations are set up in areas with air conditioning, but anything that provides relief from the heat will reduce risk.

If heat stress hazards threaten your indoor workers, control measures include better indoor cooling and improved air circulation. This could be as simple as opening some windows or setting up cooling fans in areas where heat is regularly trapped.

5) Creating a Heat-Specific Emergency Action Plan (EAP)

EAPs are an essential planning document for workplaces with any hazards, but they can be developed for specific types of hazards in mind, including heat hazards.

If heat hazards are present on a jobsite, a heat-specific EAP will improve emergency readiness should heat illness strike. To ensure maximum readiness, heat-specific EAPs should include the following:

  • A section detailing the location and nature of all heat hazards
  • A section with an inventory and location of all heat emergency supplies
  • A section detailing what actions workers should take in the event of an emergency
  • Contact information for a nearby medical facility
  • The names and contact information of anyone in charge of developing the EAP

Once your heat-specific EAP is complete and signed off on, it’s the responsibility of safety personnel to introduce the plan to workers and train them on proper procedures. Time is critical when heat illness occurs, so it’s important that your employees are ready to put the EAP into action instantly.

6) Training Workers to Recognize the Signs of Heat Illness

When heat illnesses do emerge, the first person to notice is almost always another worker. That means if your employees are trained to recognize heat illnesses, your organization will manage a better emergency response.

Signs of heat illness include the following:

  • Weakness
  • Loss of balance
  • Slurred speech
  • Irritability
  • Heavy sweating or a complete lack of it
  • Elevated body temperature
  • Confusion
  • Loss of consciousness

Heat exhaustion and heat stroke present with similar symptoms – but heat stroke presents with more severe symptoms that can quickly lead to a medical emergency. If your employees can catch heat illnesses before they progress to heat stroke, permanent (even fatal) injuries can be avoided.

Mitigate Heat Stress Hazards with the Right Control Measures

Heat stress puts workers, and your organization, at risk. Excessive heat poses a risk that’s invisible, silent and odorless – so awareness is key. Your organization can maintain that awareness with proven control measures including safety signage, LCTs, altered work schedules, cooling stations and safety training among them. These control measures are generally simple and inexpensive to implement, so there is no reason to ignore heat hazards and the dangers they pose.

Heat Stress Control Measures FAQ

What is the difference between engineering and administrative controls for heat stress?

Engineering controls change the environment: shade, ventilation, fans for air movement, air conditioning, and shielding or insulating process heat from ovens, furnaces and steam lines. Administrative controls change how the work is done: scheduling heavy tasks for cooler hours, work and rest cycles, job rotation, acclimatization for new and returning workers, water and rest break schedules, and training. Use engineering controls first where they are feasible, then layer administrative controls on top. Personal cooling gear such as cooling vests and neck wraps comes last and supports the other two rather than replacing them.

How often should heat conditions be checked during a shift?

Check at the start of the shift and keep checking through the day, because the heat index usually climbs into the afternoon. Check again when the crew moves to a new area, when the work gets heavier, and anywhere indoors near process heat, where conditions can be worse than outside. Tie each reading to a specific action in your heat plan so the check changes what happens next. A liquid crystal thermometer on a Heat Aware Card gives workers a reading in seconds wherever they are.

How do work and rest cycles reduce heat stress?

Rest gives the body time to shed the heat it builds up during work. Breaks should get longer and more frequent as the heat index rises, as the workload gets heavier and when workers are in heavy protective clothing. The rest has to happen somewhere cooler, in shade or a cooling area with water, not at the hot spot where the work is. Write the schedule into your heat plan so supervisors are not improvising it on the hottest day of the year.

Does work clothing and PPE affect heat stress?

Yes. Heavy, non-breathable or layered clothing, flame-resistant gear and chemical protective suits trap heat and keep sweat from evaporating, which is how the body cools itself. Treat workers in that gear as higher risk at a lower heat index than the rest of the crew, with more rest, more water and closer monitoring. Never have workers remove required protective equipment to cool off. Adjust the schedule, the pace and the rest breaks instead.

Who should be responsible for heat controls on a jobsite?

Name one person for each crew and shift. That person checks conditions, makes sure water and shade are in place, enforces the break schedule, keeps a close eye on new and returning workers, and starts the emergency action plan if someone gets sick. Supervisors need training to do this well, and the crew needs to know who that person is. A short heat stress toolbox talk is an easy way to cover it before the shift. For the signs to watch for, see our guide to heat stress causes, symptoms and prevention, and for the employer’s obligations, see OSHA requirements for heat safety.

How Can Road Construction Crews Stay Out of Heat Stroke Danger?

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Heat stroke is a risk in all forms of construction, but it’s elevated for road construction workers. The job involves bursts of heavy labor, and if construction is being done during the day, there may not be shade nearby. On major highways, the nearest source of shade may be across several high speed lanes of traffic. For these workers, it may seem like there’s no escape from the sun.

During the paving process, heat is more of a concern, as asphalt is applied at temperatures of 200 degrees Fahrenheit or hotter. That’s a lot of radiant energy, exposing construction crews to elevated temperatures.

Road construction workers need protection from heat exhaustion and heat stroke. If not treated promptly, heat stroke can lead to long-term disability or death, so prevention is critical. To do that, construction sites need the right processes and the right equipment.

Keep an Eye on the Thermometer

The first step in preventing heat illness is knowing when the heat is too much. Every worksite should monitor temperature constantly, and be ready to take measures when the heat index is elevated. The more people watching the temperature, the better, as preventing heat illness should be everyone’s goal, from supervisors to the crew. It’s especially important that workers know the temperature, as they are usually the first to notice signs of heat illness in other workers.

Heat cards are an ideal way for everyone at the site to monitor the temperature. Heat cards are embedded with thermochromic liquid crystals, or LCs, and these crystals alter their orientation as the temperature rises and falls. This causes them to change color, and they are accurate within a single degree Fahrenheit. Heat cards allow for temperature monitoring on demand at a glance, and they can also be printed with company branding, reference information or emergency contacts. This can be lifesaving if a worker is found debilitated by heat stroke and cannot be easily moved.

Information is Critical

Many companies are integrating heat illness prevention into their occupational safety programs, and a major part of these programs is information. It’s essential that everyone know what the company’s processes are regarding heat illness prevention, risk reduction and what to do in the event of an emergency.

Efforts in informing an entire workforce should be multifaceted. Verbal instruction and training are important, but so are reminders. Some construction sites pass on safety policies but fail to reinforce them, which leads to lapses in safety. A simple solution to this is posting signage around the worksite that provides critical safety information.

As long as workers know how to prevent heat illness, doing so is easy. Calculating the heat index, gauging fluid intake and scheduling rest breaks are effective at preventing heat stroke. Informational signage and heat cards can help remind workers to do all three.

There’s Safety in the Shade

The chances of heat stroke elevate when workers are directly exposed to the sun, and road construction workers are exposed to the sun for long stretches of time. There’s no getting away from it in some cases, and it’s impossible for people to cool down if they can’t. What’s worse, if shade is available, it may only be available for a short time, and that shaded area recently exposed to the sun will still be radiating heat.

Construction workers can avoid this problem by setting up tents on the jobsite. Tents are simple, yet perfect solutions to the no-shade problem, as long as companies select the right tent. In this case, the right tent is one that’s built with a metal frame, and preferably a heavy duty, aluminum frame. Aluminum is light, so it’s easy to carry and maneuver, and it’s corrosion resistant, so it can handle exposure to weather and air that’s heavy with salt.

Tents can be set up quickly and moved as needed, so as work shifts to another section of the road, the tents can be broken down and moved easily. Tents can also be kept in one spot throughout the day, and that keeps it cooler. Some tents come with walls, too, and this can insulate the inside from the heat outside. Combine the tent with a powerful fan, set up a hydration station inside, and workers have a place they can retreat to for rapid cooling.

Road construction crews are constantly challenged by heat stress, whether it comes from the environment, from exertion or from heated paving materials. Construction companies, their management and their crews must be aware of these heat risks at all times, as they can lead to debilitating heat exhaustion and potentially deadly heat stroke. With the right equipment and processes, though, it’s possible to stay on top of heat-related hazards and ensure workers are protected from heat stroke.

Five Ways to Improve Hydration in Heat and Keep Workers Safe

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Keep Your Workers Safe with Proper Hydration

In 2013, there were more than 16,000 reports of heat illness that were serious enough to result in at least one day of missed work, according to the U.S. Office of Compliance. Among those reports, there were 38 fatalities due to heat illness. It is up to employers and supervisors to prevent these potentially-fatal outcomes, and the Occupational Safety and Health Administration, or OSHA. OSHA’s General Duty Clause requires employers to provide a place of employment that is free from recognizable hazards.

Heat is a recognized danger, but employers can counter it by keeping their workers cool and hydrated.

Five Ways to Improve Hydration in Heat

As workers exert themselves, they rapidly lose water in the form of sweat. This is a critical means of controlling body temperature, and without constant rehydration, it’s a mechanism that eventually fails. Once the body can no longer control its temperature, heat illness is imminent, so it’s critical that it never gets to this point. Here’s how employers can ensure their workers are safe from the heat at all times:

  1. Verify that workers are rehydrating – It’s common for workers to neglect rehydration while focused on completing a task. Dehydration is something that usually emerges slowly, so workers may not realize how dehydrated they are until it starts causing problems. This is why workers shouldn’t be the only line of accountability when it comes to hydration.
    Employers can learn a lot just by observing their employees and determining which ones are neglecting rehydration. Many of these workers would be happy to take a break and rehydrate, but they may not realize how often they need to replenish their fluids. Employers can use reference materials, which may be as simple as a laminated card, to remind workers when it’s time to take a break.
  2. Keep track of changing weather conditions – Even a difference of a few degrees may make the difference where heat illness is concerned, so keep an eye on the thermometer. Even better, give each worker a way to keep track of the temperature so they know when they need to rehydrate more frequently. For example, when the heat index climbs above 90 degrees Fahrenheit, workers will need between 12 and 24 ounces of fluid every hour to remain hydrated. When the heat index rises above 100 degrees Fahrenheit, though, workers will need to double or triple their water intake to stay hydrated.
    If workers have their own temperature-keeping device on hand, they can react to climbing temperatures right away, and hydrate accordingly.
  3. Make use of shade – Drinking water and replenishing electrolytes are essential elements of staying hydrated, as is reducing temperatures when possible. It’s highly recommended that there is a shaded rest area on every worksite, even if that shade is provided by a tent. In fact, tents typically make the perfect shade solutions because they can be moved around when it’s convenient to do so. Tents are also a valuable source of shade when there are no other sources of shade to be had. Consider setting up a hydration station inside the tent, along with air movers to circulate air and improve cooling.
  4. Use cooling equipment – Keeping workers cool is one way to keep them hydrated, so any tools that improve cooling efforts are tools worth investing in. They don’t have to be expensive or complicated devices, either. For instance, a simple neck wrap can be soaked in cool water and applied to wick heat away from the worker. These neck wraps are inexpensive and can be used over and over. They also help workers remain comfortable as well, which enables better, more reliable performance while on the job.
  5. Know the signs of dehydration – Dehydration isn’t just a danger to the worker. Once dehydration sets in, job performance suffers greatly, to the point where the worker may become a safety risk to themselves and those around them. According to a 2015 study published by Loughborough University, being dehydrated is the equivalent of being legally drunk when evaluating job performance. Even a modest amount of fluid loss (2 to 3 percent of the body’s total) is enough to induce considerable fatigue.
    Dehydration can produce a range of symptoms, including headaches, tiredness, dizziness and an inability to concentrate. Perhaps the most obvious sign of dehydration is dark urine color. When urine takes on a darker hue, as in darker than apple juice, it’s frequently due to dehydration and reduced fluid in the urine.
    There should always be someone on the worksite to spot any signs of severe dehydration or heat illness. Oversight in this area will hopefully stop instances of dangerous dehydration before they progress into medical emergencies.

Hydration is vitally important in protecting workers from harm while on the job. It’s up to employers, then, to implement these hydration safety methods and ensure their workers are prepared to meet the summer heat.

Worker Hydration FAQ

How much water should workers drink in the heat?

NIOSH guidance for work in the heat is 1 cup (8 ounces) of water every 15 to 20 minutes, which works out to 24 to 32 ounces an hour. Small amounts often work better than a lot at once, and workers should drink on that schedule instead of waiting until they feel thirsty. Put water close enough to the work that a drink does not mean a long walk.

Can a worker drink too much water?

Yes. NIOSH advises against drinking more than 48 ounces (1.5 quarts) an hour. Drinking far more than the body is losing can dilute the salt in the blood, which is its own medical problem. Steady, regular drinking through the shift is the goal, not catching up with a large amount at lunch.

Do workers need sports drinks or electrolytes?

For most work, water is enough. When heavy sweating goes on for several hours, NIOSH notes that sports drinks with balanced electrolytes are an option to replace the salt lost in sweat, though heavy use adds sugar. Energy drinks are a poor choice, because several a day can raise caffeine enough to affect the heart, and alcohol within 24 hours of working in the heat raises the risk of heat illness.

How can a supervisor tell if a worker is getting dehydrated?

Watch for headache, tiredness, dizziness, trouble concentrating and a drop in pace or accuracy. Urine color is a simple field check: urine darker than apple juice usually means the worker needs more fluid. Dehydration builds slowly, so pair workers up and check on anyone who has skipped breaks. If a worker becomes confused or stops making sense, treat it as heat stroke and call 911.

How do you adjust water breaks as the heat index rises?

Tie the schedule to the heat index, not the thermometer alone, because humidity makes the same temperature more dangerous. The HATS-20 B version of the Heat Aware Card carries a work and rest ratio and a fluid intake chart that match the colored zones on the Heat Stress Management System sign, so every worker can see what the current conditions call for. Write the schedule into your heat illness prevention program so it does not depend on one supervisor remembering it.

Do cooling neck wraps replace drinking water?

No. A wet neck wrap can make a worker more comfortable and help shed some heat, but it does not put back the fluid lost in sweat. Use cooling gear alongside water, rest and shade, never instead of them.

Stay Safe in the Heat: Sports and Heat Awareness Tips

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Whether you’re a coach or an athlete, there are several steps you can take to stay safe in the heat. With heat-related illnesses being an ever-present concern, here are some of the ways to stay heat aware and keep players and staff safe during practices and games:

  • Know the signs and symptoms of heat illness
  • Monitor on-field conditions in real time
  • Acclimate to high-risk conditions before intense exertion
  • Assess each athlete’s overall fitness level
  • Having a backup plan during periods of elevated heat risk
  • Establishing an emergency action plan (EAP) in the event heat stroke occurs

Among high school athletes, exertion-related heat stroke is a leading cause of preventable death. According to the National Federation of State School Associations (NFHS), 18 high school athletes have died due to heat exposure in the past 10 years during practice.

Athletes of all ages are at risk, not just children, so heat awareness is paramount at every level of competition. To help with that, here are some easily implemented and effective heat safety tips:

1) Know the Signs and Symptoms of Heat Illness

Heat exhaustion and heat stroke can come on suddenly, especially when temperatures and humidity levels rise gradually. That means vigilance is the first step in preventing heat illnesses. If the team’s coaches and trainers are familiar with the signs of heat exhaustion, they can intervene before it progresses to heat stroke.

Signs of heat exhaustion include:

  • Heavy sweating
  • Cool skin that may be moist to the touch
  • Dizziness and confusion
  • Fatigue and weakness
  • Nausea
  • Headache

If not treated, heat exhaustion may develop into heat stroke, which is a medical emergency. Heat stroke presents with profound confusion, difficulty speaking, a dangerously high body temperature (more than 104 degrees Fahrenheit), and loss of consciousness.

Heat stroke deaths are completely preventable if coaches, teammates and parents act as soon as someone shows signs of heat illness.

Heat Aware's Heat Cards - HATS-20A | The signs, symptoms and treatment of heat illnesses2) Monitoring On-field Conditions in Real Time

Prompt care is important for heat illnesses, but prevention is the priority. That starts with monitoring on-field conditions and responding quickly if conditions become dangerous.

Throughout practice, take several temperature readings and pay close attention to humidity levels, wind patterns, and sun exposure. You don’t need bulky, sophisticated equipment to do this. A simple liquid crystal thermometer (LCT) can provide accurate temperature readings. LCTs are also weightless and compact, so they’re often integrated into ID badges, and because they’re cost effective, they can be distributed among coaching and trainer staff.

With temperature-taking tools like LCTs on hand, the coaching staff can keep a close eye on practice conditions and respond when they are no longer safe.

3) Acclimating to High-risk Conditions Before Intense Exertion

The vast majority of serious heat illnesses occur during the first few practices, before everyone has had a chance to adjust to the weather and activity levels. The NFHS recommends coaches implement a heat acclimation program that progresses over several weeks and prioritizes the following:

  • Shorter, less intense practices
  • Longer recovery periods between stretches of activity
  • Focusing initial practices on instruction instead of conditioning
  • Introducing protective gear slowly during initial practices

Longer breaks, plenty of water and fluids and minimal protective gear reduce the heat burden on athletes as they ramp up conditioning. This acclimation period also gives coaches the ability to identify anyone with an elevated risk of heat illness.

4) Assessing Each Athlete’s Overall Fitness Level

Prior to intense practices, it’s important for the team’s doctors to assess each athlete’s health and fitness levels. This includes identifying any medical conditions or medications that may place the person at a higher risk of heat illness. Examples include obesity, heart conditions, and certain mental illnesses (which can make it difficult to detect changes in temperature).

With this information, the team’s trainers can dedicate extra attention to anyone at elevated risk. This could include providing additional fluids, taking the athlete’s vitals more often, and developing an individualized plan for high-risk individuals.

5) Having a Backup Plan During Periods of Elevated Heat Risk

In some cases, the heat is too dangerous for any athlete to practice – regardless of fitness level. It is up to the coaching staff to recognize this and adjust accordingly. In fact, the NFHS recommends that teams have a “plan B” for those times when heat derails practice. For example, coaches may move activities to an indoor facility where air conditioning is available. Or, coaches may reduce practice intensity, switching to instruction instead of exertion.

Whatever the team’s plan B, it should be established before it needs to be implemented. Identify an alternative location or practicing method and communicate this to the entire team. That way, when the backup plan is needed, it can be quickly implemented.

6) Establishing an EAP for Heat Stroke Events

Another plan that every sports team needs is an emergency action plan for heat stroke. EAPs specify everything the team needs to know when a player develops heat stroke, including:

  • Where to take the patient for rapid cooling
  • What resources are available for treating heat stroke, and where they are located
  • Procedures for treating the patient, depending on presentation of symptoms
  • Who to contact if a player experiences heat stroke
  • Contact information for the team’s doctor or medical staff

An EAP formalizes the team’s response to a heat-related medical emergency and encourages a rapid response when it’s needed most. Serious complications due to heat stroke may be averted with prompt treatment, and an EAP increases the likelihood that it will be delivered.

Stay Heat Aware So the Team Stays Safe During Summer Sports

When the heat is on during the summer, so is the risk for athletes. To keep players safe and in the game, it’s up to everyone to practice heat awareness. That starts with vigilance – tracking on-field conditions, specifically. Temperature-taking tools like LCTs can make it easier to monitor conditions without stretching the team’s budget.

Why Heat Related Workplace Injuries Need to be a Top Priority to Occupational Health and Safety Managers

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Heat related workplace injuries are a threat to employees in a number of heavy-duty industries, including:

  • Construction
  • Manufacturing
  • Oil and gas
  • Transportation
  • Warehousing
  • Food processing
  • Mining
  • Agriculture
  • Firefighting

Workers in these industries are at elevated risk of developing heat illnesses, such as heat exhaustion and heat stroke, elevating the need for safety measures being implemented for workplace injury protection. Occupational health and safety managers are responsible for implementing this heat-related protection, and there are proven methods for doing so. Here, we’ve included four ways occupational safety managers can make heat injury prevention a priority for their workplaces.

Heat Hazards in the Workplace: By the Numbers

The Bureau of Labor Statistics (BLS) is responsible for tracking workplace injuries, including heat related injuries. According to its 2011-2020 data, there were 33,890 heat injuries severe enough to result in missed work time. That’s an average of just under 3,400 heat-related illnesses in the workplace annually. The BLS’s fatal occupational injury census also estimates that between 1992 and 2021, 999 workers died due to environmental heat exposure. That’s an average of 33 fatalities every year.

However, the BLS data is believed to vastly underestimate the real problem due to the following factors:

  • Limitations in employee and employer reported data
  • Different interpretations of what constitutes a heat injury by medical personnel
  • Unreported health conditions that may have been exacerbated by heat exposure
  • Latent, late-onset symptoms caused by the heat illness
  • A large variance in heat illness symptoms and their influence on decision making

Together, these factors make it impossible to accurately gauge heat risks, and it’s likely that the number of heat injuries and illnesses is higher than reported.

Four Things Occupational Safety Managers Can Do to Make Heat Illnesses a Priority

Thousands of workers are injured every year by excessive heat exposure and dozens are killed. For businesses operating in high-risk industries, heat safety can be a matter of life and death. Here’s what employers can do to protect their workers from heat-related illness:

1) Establish a heat-specific safety plan

Employers are not required to author a safety plan, but they do help with regulatory compliance and are therefore highly recommended. A heat-specific safety plan goes a step further and prioritizes heat injury prevention.

Your heat safety plan should include the following:

  • Documentation that identifies the location and nature of all heat hazards. This could be a list, a diagram, a floor plan, or other supporting documentation
  • An inventory of all heat related medical supplies and their location
  • A list of emergency procedures should a worker develop heat illness
  • Contact information for a nearby medical facility
  • The names and contact information for everyone responsible for enforcing the safety plan

Your company’s heat safety plan is a primary safety training resource. As such, it should be used by managers to enforce heat illness prevention efforts and ensure all workers abide by them.

2) Make heat safety a priority with your safety signage

Heat safety is a matter of vigilance. It’s important for workers to always be prepared when environmental heat has reached unsafe levels or when exertion may cause unsafe conditions. To ensure your employees are always ready, consider investing in additional safety signage. Employers are required to point out potential workplace hazards, and safety signage is a proven way to do this.

Occupational safety signage can be customized for heat hazards and used to point out where workers are at a high risk of heat exposure. For example, such signage would be a good fit near:

  • Ovens
  • Furnaces
  • Foundries
  • Boiler rooms
  • Interior areas where sunlight is present
  • Areas where high exertion work is present

By placing heat safety signage near these areas, occupational health and safety managers can ensure their employees are on alert around high-risk areas.

3) Equip your workers with heat safety resources

Employees should have easy access to cooling stations that supply water, shade, air conditioning and rest. If a worker is affected by heat stress, moving them to one of these cooling stations is recommended for a rapid first line of treatment. Workers should also be given regular breaks where they can recover at a cooling station.

In addition to well-stocked cooling stations, occupational safety managers can protect their workers by providing them with valuable information. As the temperature and workplace conditions change, it’s important for workers to identify these changes as soon as they occur. One way to do this is to supply employees with temperature-taking tools like liquid crystal thermometers (LCTs). LCTs are light, easy to use and provide an accurate temperature reading within seconds. LCTs can also be integrated into employee TWIC cards, so workers can put them in an open toolbox, wear then on lanyards, or carry them in a pocket. In seconds, workers can get an accurate reading of current workplace conditions and adjust accordingly.

4) Train employees to recognize and respond to the signs of heat illness

No matter what heat safety measures your company has in place, your workers must be ready to respond to heat illness when it emerges. That means knowing the signs and symptoms of heat exhaustion and heat stroke. Those symptoms include:

  • Excessive sweating or complete lack of it
  • Fatigue
  • Nausea or vomiting
  • Confusion
  • Loss of coordination
  • Slurred speech
  • Elevated body temperature

If any signs of heat illness are present, your workers should have an emergency action plan (EAP) that kicks in immediately. Your EAP should specify any emergency response measures, point out the location of any emergency medical supplies, dictate where workers are to receive medical attention and who should be notified in the event of a heat related emergency.

Before beginning work in any hazardous environment, employees should be trained on the company’s EAP and on the nature of heat illness. New workers should also have time to acclimate to workplace heat sources and the company’s heat safety processes.

Make Heat Related Workplace Injuries a Priority With Improved Safety Standards

Heat hazards are a threat to workers, and the consequences of excessive heat exposure can be fatal. Occupational health and safety managers are the most important line of defense against deadly heat hazards, but safety managers have measures they can take to protect employees. Developing a heat safety plan, installing safety signage, investing in heat safety resources and focused safety training can make the difference in shielding workers from deadly heat exposure on the job.

Why Heat Awareness Still Matters in Winter

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Why Heat Awareness Still Matters in the Winter

Many workers are still exposed to heat risks during the winter, even when temperatures are plummeting outside. That’s because indoor workers may labor in high-heat environments fraught with potential hazards, which is why heat awareness still matters in winter.

Employers are responsible for identifying risks on the job and protecting employees from them. This includes putting together a heat safety plan, adequately training workers on that plan, and providing workers with the resources they need to protect themselves, regardless of the season.

Which Workers are at Risk of Heat Illness During the Winter?

Some indoor work environments put workers at a high risk of heat illness year-round. Some of those industries include:

  • Bakeries and commercial kitchens
  • Manufacturing centers with intense heat sources, such as concrete plants
  • Iron and steel foundries
  • Facilities with boiler rooms – such as electrical utility stations
  • Commercial laundries
  • Warehouses

Workers in these environments require additional protections from heat hazards, even during the winter. Consider this – the California Occupational Safety and Health Administration determined that, from 2011 to 2018, of the 20 workers who died of heat exposure, eight of them were indoor workers. Winter weather or not, indoor heat risks persist through the season.

Common Causes of Indoor Heat Exposure

Many employers make the mistake of assuming that because their workers are inside, they are shielded from extreme temperatures. But this isn’t always the case. Indoor workers may still be affected by excessive heat due to the following:

  • Intense local heat sources – Furnaces and ovens can output intense blasts of heat and create pockets of dangerous thermal activity. Bakeries, food processing centers and foundries are examples. In these settings, focusing temperature sensors and safety efforts near high-thermal zones makes sense.
  • Heavy exertion – Extended heavy exertion can raise a worker’s body temperature to dangerous levels, even during the winter. Employers cannot assume that low ambient air temperatures are enough to protect workers engaged in heavy duty work. This is especially true for new workers who haven’t had time to adjust.
  • Protective wear and equipment – Protective clothing and equipment (PPE) reduces air flow to the worker’s skin. As such, people wearing PPE are at risk of heat illness when exerting themselves. External heat sources may worsen the effects of PPE.
  • Insufficient or inefficient cooling technology – Poor air circulation and insufficient cooling are common causes of indoor overheating. It’s important to verify that your facility’s HVAC technology can handle the heating load that your workers and equipment generate. Regular maintenance is also essential and is considered part of an employer’s general duty to their employees.

When indoor workers experience heat illness – heat exhaustion and heat stroke, for example – the above factors are typically present.

Federal and State Safety Standards for Occupational Heat Hazards

Federal and state agencies recognize the potential for heat illness during the winter. The Occupational Safety and Health Administration’s (OSHA) general duty clause requires employers to provide a work environment that is free of hazards that could cause serious or fatal injury. This extends to hazards that could cause heat illness.

Some states have implemented additional heat hazard provisions to protect workers. Those states include:

  • California
  • Colorado
  • Minnesota (with specific provisions for indoor heat safety)
  • Oregon
  • Washington

This demonstrates that heat awareness still matters in the winter for employers.

How to Protect Workers from Heat Illnesses During the Winter

Heat is an invisible killer, but there are clear steps that employers can take to prevent heat from threatening employees. Those steps include:

  • Developing a heat-specific safety plan – OSHA does not require employers to have a detailed safety plan in writing, but it does require all employers and managers to be aware of potential workplace hazards. So even though it isn’t required, developing a heat safety plan can help organize your company’s safety efforts and protect your crew. If heat exposure is a risk to your indoor workers, a heat-specific safety plan will ensure no heat hazard is left unchecked. Your plan should identify all potential heat hazards in the work environment and specify measures to protect people from them. Further, your plan should name who is accountable for enforcing those measures. This plan will serve as the foundation for your heat safety processes. It will also be used to train workers.
  • Training employees on heat safety protocols – Once your company has established a heat safety plan, you will need to communicate the plan to workers. Set aside time to train workers on heat risks as this will encourage employees to take ownership of their own safety and the safety of others.
  • Acclimating new employees – Workers who haven’t had time to adjust are more likely to experience heat illness. Most occupational heat-related deaths involve people who have only been on the job for a short time. As such, it is extremely important for employers to give new workers a chance to acclimate to elevated temperatures. This includes gradually scaling up the length of work shifts, providing additional breaks and closely monitoring new workers for any signs of heat illness. Free access to water and cooling stations are also critical.
  • Recognizing the signs and symptoms of heat illness – Although heat illness can emerge suddenly, there is usually a short window during which it can be treated before it becomes an emergency. However, your workers and managers must be familiar with the signs and symptoms of heat illness to act. Heat exhaustion is characterized by excessive sweating, cold or clammy skin, weakness, fatigue, confusion, nausea, vomiting, a weak pulse, headaches and dizziness. Heat stroke presents with red and dry skin, body temperature in excess of 103 degrees, a strong pulse, profound confusion and dizziness, slurred speech and loss of consciousness. The goal for managers and coworkers is to notice when a worker may be affected by minor heat injuries. When detected, removing workers for prompt treatment is critical. Vigilance saves lives.
  • Monitoring indoor temperatures and work conditions – Being proactive is important if heat is a threat. Work conditions can change rapidly and become hazardous before anyone realizes it, especially if there aren’t heat monitoring resources in place. Temperature-tracking tools can alert safety personnel to potentially dangerous conditions indoors. Temperature sensors should be placed near known heat sources and used to determine when heat levels are unsafe. For optimal safety, empower workers to track temperatures on their own. A simple and cost-effective way to do this is with TWIC cards embedded with liquid crystal thermometers (LCTs). LCTs provide a quick, accurate temperature reading. TWIC cards are inexpensive, lightweight, and can give workers advance notice of elevated temperatures before safety personnel need to intervene. This can give your workers the advantage in identifying dangerous conditions before they cause heat illness.

The above measures will improve your team’s ability to respond to heat-related emergencies before they cause serious or fatal injury. Or, even better, prevent those emergencies from happening in the first place.

Heat Awareness Still Matters in Winter, So Keep Your Crews Prepared

Excessive heat can cause serious injury or death, even during the winter. As such, employers are required – as per OSHA’s general duty clause – to put heat safety measures in place. Fortunately, these measures are simple and inexpensive to implement. They include devising a heat-specific safety plan, raising heat awareness among workers, and investing in safety resources like LCTs and other temperature monitoring tools.

Heat Awareness in Manufacturing Facilities

Heat Awareness in Manufacturing Facilities

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The Importance of Heat Awareness in Manufacturing Facilities

Heat illnesses and injuries are on the rise in the U.S., and this trend is also true of indoor workers. Shielded from outdoor heat exposure, it’s common for employers to overlook the importance of heat awareness in manufacturing facilities.

Given the severe, potentially fatal nature of heat illness, employers are required to take measures in preventing and responding to heat illnesses experienced by their employees.

Regulators are Emphasizing Improved Heat Awareness and Safety in Manufacturing Facilities

According to the EPA, the number of heat waves (defined by a four-day stretch of high temperatures above the 10-year average) has tripled since 1990. Unsurprisingly, heat injuries and illnesses have climbed alongside this trend, leading OSHA to begin discussions about national heat safety standards.

There are early signs that OSHA is getting tougher in this regard. In October 2021, the administration published an Advance Notice of Proposed Rulemaking (ANPRM) – the first public step that OSHA takes before implementing new safety standards. The October 2021 ANPRM was specific to outdoor and indoor heat hazards, so it’s clearly an OSHA priority.

In April 2022, OSHA enacted a National Emphasis Program (NEP) that included three participating states – California, Minnesota, and Washington. The NEP is a three-year program that gives OSHA authority to perform on-the-spot workplace inspections for heat hazards. OSHA has inspected more than 1,500 businesses already in this fashion, and the resulting information will be used to further develop heat safety standards.

In the most recent update in November 2023, OSHA surveyed small businesses and interfaced with small business advocacy groups to gain further insight into heat safety implementation.

While it’s true that government maneuvers can take a long time to realize, there are clear signs that OSHA will launch new heat safety standards in the near future.

Common Heat Hazards in Manufacturing Facilities

OSHA’s interest in heat safety extends indoors as there are several hazards specific to manufacturing facilities and industrial centers. Heat-related risks may be elevated among employees working indoors, especially if the following factors are present:

  • Heat generating equipment and machinery – Milling machines, turning machines, presses and grinders all output significant amounts of heat that spills into the environment and puts workers at risk of heat illness. If the equipment is poorly insulated, it can cause an immediate heat hazard around the machinery’s operating area.
  • Other radiant heat sources – Other sources of radiant heat in manufacturing facilities include ovens, furnaces, and kilns. Each can output intense levels of thermal energy, requiring workers to don protective gear that increases heat risks.
  • Lack of air movement – Air circulation is essential for venting heat out of the facility and preserving safe working environments. In manufacturing centers, strategic fan and HVAC vent placement will help circulate cooler air through the facility. In warehouses, hangars, and other large industrial centers, opening up a large bay door can promote better air circulation.
  • Constant physical labor – Modern manufacturing facilities rely on automation to an extent, but there is still plenty of manual labor happening. With workers in constant motion, exertion-related heat must be factored in. If your employees do a lot of lifting, pushing, pulling, or carrying, your facilities will need measures in place to offset that additional thermal output.
  • Heavy protective clothing – Personal protective equipment (PPE) may include heavy clothing that traps heat, causing the worker’s body temperature to rise, even if they’re standing in one spot. If there are other hazards at your facilities that demand safety wear, consider the additional thermal burden on employees.
  • Exposure to sunlight – Sunlight means heat, so if it’s cascading in through windows or open doors, your facilities will have additional thermal energy to contend with. It’s easy to dismiss a patch of sunlight here or there in a manufacturing facility, but it can be a threat if additional heat risks are present, like poor air circulation or heavy protective wear.

These hazards are in addition to extreme outdoor temperatures, which can also influence the relative heat levels inside buildings. Clearly, there are several heat-related risk factors to account for, but there are steps employers can take to lower the risk of heat illness affecting their employees.

How to Improve Heat Awareness in Manufacturing Facilities

The key to preventing heat exhaustion, heat stroke, and other heat illnesses is awareness. If workers are aware of heat stress symptoms and dangers, they can take the appropriate action before a situation becomes critical. Here is what employers can do to improve heat awareness in manufacturing facilities:

  • Developing a heat illness prevention plan – Every workplace must have a safety plan in place per OSHA regulations. With the level of heat danger and heat fatalities on the rise, employers are also encouraged to develop a heat-specific safety plan that tackles heat illnesses specifically.

This plan should include everything else on this list, as well as the plan’s training and implementation procedures.

  • Training each worker on the plan’s details – Every employee should undergo heat safety training, using the procedures and practices derived from your heat safety plan. Training typically includes pointing out heat hazards, noticing the symptoms of heat illness, the location and use of all heat safety resources (such as water or cooling stations), and emergency procedures should severe heat illness occur.
  • Identifying where heat hazards are likely to emerge – All heat safety plans should point out the location and nature of any heat hazards present at the facility. Consider including maps and floor plans to assist with this communication to facility staff and visitors.
  • Keeping an eye on environmental conditions – Working conditions can change quickly, so it’s important for your staff to monitor temperatures in real time. As environmental conditions change, your heat safety plan may call for additional measures, such as implementing work rotations or mandatory cooling breaks.
  • Investing in heat safety resources – An inexpensive and effective way to track temperature is to provide employees with liquid crystal thermometers (LCTs). LCTs are accurate within a degree or two and can provide a reading within seconds. The thermometers are practically weightless and can be scaled down to fit into a TWIC card or something similar. With LCT-integrated TWIC cards, your workers can wear their temperature-tracking tool on a lanyard or place it in a pocket.

Additional heat safety resources include heat safety signage, which is used to point out high-risk areas, first aid stations, showers, and other points of interest when a heat emergency develops. Posted signage keeps that information in front of workers at the moment they need it, which is what makes it useful on a plant floor where conditions change through the shift.

  • Develop heat emergency protocols – Even with robust prevention methods in place, heat illness remains a threat to industrial workers. A heat safety plan should formalize any emergency response to optimize response time and effectiveness.

Emergency measures typically include moving the worker to a cool area, applying cool water or towels to the skin of the affected employee, administering fluids if possible, and contacting emergency medical personnel right away. It’s standard practice for a heat safety plan to include contact information for a nearby hospital or medical facility.

Heat Awareness in Manufacturing Facilities Can Save Lives

Heat illnesses and fatalities are becoming more common for workers across many industries and in many work settings. This includes indoor work settings like manufacturing facilities.

It’s a common but potentially costly mistake for facility operators to discount the severity of potential heat hazards, but there can be fatal consequences.

A proven approach to undercutting those hazards is preparation. Specifically, preparing workers with heat-specific training and resources. LCTs and safety signage are two examples of budget-friendly items that can boost heat awareness and safety in manufacturing facilities. Speak with your heat-aware specialist to see how you can protect your employees.

The Benefits of a Heat Management System

The Benefits of a Heat Management System

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Advantages of Implementing a Heat Management System

Thermal threats are mounting at worksites around the country. Heat waves are increasing in intensity and duration, according to the World Health Organization, and this trend will likely continue, making a heat management system a must for worker safety.

Work crews are bearing the brunt of this extreme heat, leaving them exposed to potential heat illnesses that can cause permanent, even fatal injury.

A heat management system, when properly implemented, is designed to push back against this risk. There are numerous elements that may be included in a thermal management system, but the bottom line is that they provide workers with resources, processes and information that can prevent heat illness.

Here, we’ll address what an ideal heat management system typically includes and how it can support worker safety.

Why Heat Management Matters

Thermal stresses are largely dictated by ambient weather conditions. Temperature, relative humidity, sun exposure and wind speed are all important considerations. Weather, though, is only one factor. Thermal risks are also exacerbated by activity levels, the worker’s age and health, clothing or protective equipment, the presence of major heat sources (furnaces, for example), and other considerations.

With the above factors in play, there may be an elevated risk of heat illness even when ambient conditions aren’t a factor.

Regardless of where excess heat is coming from, if thermal dangers are present on your worksite, it’s time to develop a heat management system.

Heat illnesses range in severity – from minor heat rash, to heat syncope (brief loss of consciousness), and even life-threatening conditions like heat stroke. According to the Bureau of Labor Statistics, dozens of workers are killed by heat illness every year and hundreds of thousands are injured. Given the nature of heat injury reporting and its nonspecific symptoms, it’s highly possible that these numbers are lower than reality.

Major and fatal injuries are typically the result of heat stroke. As the end stage form of heat illness, heat stroke can develop rapidly – seemingly out of nowhere in some cases – but it’s common for it to emerge and intensify over a short period of time. That means deadly heat illnesses can be prevented with the right precautions and treated with the right procedures. Determining what those precautions and procedures should look like – that’s the core of a heat management system.

What Should be Included in a Heat Management System?

Heat management systems are meant to be a comprehensive defense against thermal stresses. Here’s what that defense system should include:

  • A heat specific safety plan – Employers are required to have safety plans in place to maintain OSHA compliance. These plans typically address all the worksite’s hazards in a general way, but on sites where heat hazards are commonplace, it’s worth developing a heat-specific safety plan.

    A heat-specific plan points out the number, location and nature of heat hazards on the project site. This could be the location of heat sources or areas where poor air circulation or increased sun exposure may trigger heat illnesses.

    A heat-specific safety plan will also designate who is responsible for enforcing heat safety protocols (and their contact information), as well as an inventory and location of all medical resources dedicated to treating heat illness. Contact information for a nearby medical facility should also be included in such a plan.

  • Medical monitoring – Medical monitoring includes health screening prior to starting work on a project, and periodic checks thereafter. The goal of medical monitoring is to identify workers who may be at an elevated risk of heat illness. Safety countermeasures can be taken in response to this information.

    On worksites where heat risks are elevated, continuous medical monitoring (watching worker vitals) may be necessary.

  • An emergency action plan (EAP) – An EAP is required by OSHA on hazardous worksites and details what to do in the event of an emergency. EAPs are used to detail all potential hazards on a worksite, including heat emergencies. In this context, an EAP will dictate how to immediately respond to severe heat illness, what resources to use, and how to treat the condition until medical assistance can be secured – as well as how to seek medical assistance from a nearby medical facility.
  • Information resources – Information resources include occupational safety signage and heat monitoring tools. Safety signage and decals are excellent, ever-present reminders to take note of heat hazards and to take proper measures (like drinking enough fluids) to avoid heat illness.

    Monitoring heat levels is also critical, as ambient conditions can cross into dangerous territory gradually, often leaving workers caught unaware.

    One way to prevent this from happening is to equip workers with temperature monitoring tools they can easily and reliably use. A popular option is to provide field workers with liquid crystal thermometers (LCTs), as these can be embedded in a TWIC-style card. LCTs are accurate within a couple of degrees and can provide a reading within seconds. As TWIC cards are practically weightless and are easy to carry (using a lanyard or just placed in a toolbox), they are an ideal choice for busy workers who cannot leave their station.

  • Engineering controls – Engineering controls are used to mitigate the intensity of heat hazards or to help workers manage their effects. For example, providing cool, potable water at cooling stations, setting up fans or air conditioning, providing shade and reducing worker exertion by providing powered equipment (a forklift, for example) are all ways to reduce heat’s impact.

Employee Education and Acclimatization are also Important Factors of Heat Safety

The majority of severe heat illnesses occur in new workers. There may be several reasons for this, but it’s common for new workers to push themselves harder at first because they aren’t aware of heat dangers – or want to demonstrate their value to the team.

Given this fact, more employers are prioritizing acclimatization and safety education when bringing on new workers. Here’s what each includes:

  • Safety education – When a heat safety plan is modified or when new workers are brought on, it’s time to educate. Specifically, education on what the company’s heat safety policies are, what heat illness symptoms to look for, what to do in the event of a heat emergency, what safety resources are available, and how to use those resources. The goal is preparedness, so workers are ready if a heat emergency does occur.
  • Acclimatization – During the acclimatization process, new workers are required to slowly ramp up their activity over several days. A standard approach is to shorten work shifts for the first couple weeks of the project and to give new workers additional breaks to recover from heat exposure.

    During this time, the worker should be closely monitored for any signs of vulnerability to heat illness, and to ensure they follow proper heat safety protocols.

If Properly Designed and Implemented, a Heat Management System Can Save Lives

Heat is one of the most difficult hazards to avoid. During some parts of the year, heat is literally everywhere and often intense enough to cause serious illness if not accounted for.

Employers can protect their workers by investing in a thermal heat management system. By ensuring the right planning, equipment, and resources are in place, your work crews will always be aware and ready for extreme heat.

Why Heat Awareness is Essential for Occupational Safety Managers

Why Heat Awareness is Essential for Occupational Safety Managers

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Heat-related deaths are reaching new heights in the U.S., in part due to rising temperatures. Intense heat exposure also threatens workers, but they have more to contend with than environmental heat. Exertion-related heat should be considered, as well as heavy work clothing.

For occupational safety managers, these factors must be accounted for, as they can add up to serious heat illnesses like heat exhaustion and heat stroke.

When Temperatures Rise, Heat Awareness Should As Well

Many work settings can be characterized as a thermal energy-rich environment. Construction sites, manufacturing facilities, outdoor warehouses and quarries are just a few examples of such worksites, but excess heat exposure can occur anywhere – even in office buildings.

Wherever heat hazards do emerge, heat illnesses are sure to follow if safety managers don’t take the proper precautions. These illnesses can manifest in one of several forms – heat rash is an example. For safety managers, though, the principal concerns are heat exhaustion and heat stroke.

Heat exhaustion and stroke share many of the same symptoms, including mental symptoms such as confusion, altered mood, slurred speech, dizziness, or loss of consciousness. Both heat illnesses require immediate intervention, but heat stroke is a medical emergency that can leave workers permanently, perhaps fatally injured.

Heat Stress is Dangerous for Workers and Costly for Companies

Dozens of workers are killed by excess occupational heat every year, and thousands more are injured. The human cost of lax heat safety measures is severe, even when taking fatalities out of the equation.

Heat-related injuries can leave workers unable to recapture their prior productivity. According to the World Health Organization, about 2 percent of all working hours every year are lost due to heat stress – a huge bite that makes heat one of the country’s biggest productivity sieves.

For employers, protecting worker health is of paramount importance. What’s also important is ensuring production benchmarks are hit. Heat hazards can get in the way of that, but occupational safety managers can mitigate heat dangers if they maintain awareness of heat hazards and implement safety measures to mitigate them.

How Occupational Safety Managers Can Protect Employees from Heat-related Injury

Heat is dangerous, in part, because it is insidious. It slowly increases in intensity until it’s enough to overtake workers. The only way to protect against this subtle, creeping danger is with vigilance. If everyone at the worksite, including safety managers, are committed to spotting and mitigating heat risks, then it will be easier to protect employees – and easier to respond to a heat emergency if one does arise.

Occupational safety managers are largely responsible for establishing heat awareness and establishing risk-reduction initiatives. Such initiatives may include:

  • Developing a heat-specific safety plan – OSHA requires employers to have a site safety plan that addresses all risks at the worksite. This general safety plan is designed to cover all hazards, but there’s nothing stopping employers from developing hazard-specific safety plans to better mitigate the most prevalent or dangerous concerns.

    At worksites where heat exposure is an ever-present threat, a heat-specific safety plan makes sense. Inside a heat-specific plan, safety managers can identify where heat hazards are the most severe and what managers can do to protect against them. This includes pointing out vital resources (first aid stations, showers, etc.), splitting workers and safety managers into working groups for accountability purposes, and listing out emergency procedures should a worker experience heat illness.

  • Organizing heat safety training prior to the project’s start – Safety managers are responsible for keeping all employees and supervisory personnel on the same page regarding safety. This is also true of heat safety, and the best way to ensure this preparedness is with adequate pre-project training.

    Heat training doesn’t need to be complicated or last long – it merely needs to reinforce heat risk mitigation procedures. The value here is boosting heat awareness among workers and managers so everyone is prepared in the event of an emergency.

  • Assessing risk on a worker-by-worker basis – People respond to heat exposure differently, and this varied response should be accounted for so the most vulnerable workers can be properly protected.

    Age, fitness level, overall health, experience, and role all factor into a worker’s vulnerability to heat. Prior to beginning work, these factors should be taken into consideration for each worker, so safety-first work rotations and break patterns can be established.

  • Acclimating workers during the project’s early phases – The majority of heat-related worker deaths and injuries occur in the first couple weeks of a project’s start. If employees aren’t given time to adjust to hot conditions, they are far more likely to be overwhelmed by the heat. For this reason, it’s highly recommended that safety managers slowly ramp up work activity over several days, giving workers plenty of breaks and limiting exertion during this period.
  • Ensuring workers have heat monitoring resources on them – One of the best ways to ensure workplace safety is to give workers access to temperature taking tools. As the people on the front lines against the heat, it’s critical that workers be able to remain aware of dangerous heat indexes.

    An inexpensive and reliable way to do this is with a liquid crystal thermometer (LCT). LCTs are accurate within a degree or two and can be embedded in a simple TWIC card for maximum usability. Within seconds, workers can get an updated look at ambient temperatures and take steps to protect themselves from dangerous levels of heat and humidity.

  • Prioritizing heat-related first aid resources – Safety managers are responsible for maintaining adequate first aid resources onsite, and at worksites where heat hazards are present, heat injury supplies should also be present. This includes the basics, such as cold compresses, ice packs and running water. Also consider electrolyte tablets for severe dehydration cases.

    These supplies should be easily accessed by work crews and their location marked in the heat safety plan for quick reference.

Heat Awareness is Imperative for Workplace Safety

Heat is an ever-present killer during the summer months, so occupational safety managers need to remain on their guard. They also need to remain aware of heat hazards on their worksites. And beyond awareness, safety managers must be ready to respond to heat illnesses, with adequate emergency resources and to-the-minute information provided by temperature-taking tools.

A Guide to Protecting Work Crews from the Summer Heat

A Guide to Protecting Work Crews from the Summer Heat

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As numerous heat records were shattered across the U.S. in the summer of 2023, it meant that people working outside were at major risk of heat-related illnesses like heat exhaustion and heat stroke. Heat illness is an invisible, but quite capable killer that’s caused dozens of fatalities and thousands of injuries over the past several years. And it is believed that those numbers are vastly underreported, as many heat-related illnesses and deaths fall outside the purview of government regulators.

Employers are responsible for protecting their crews from heat hazards, and these protective measures must be reinforced at every level of the organization. In this guide, we’ll address what steps contractors can take to safeguard the health of their crews.

Judging Heat Conditions on Site: Don’t Focus Only on the Temperature

Elevated temperatures are an obvious heat-related danger, and as such, it’s important for supervisors to keep an eye on the thermometer. But there’s more to heat risk than temperature alone, as humidity, solar exposure, and wind speed all play a role as well.

For example, heat index values factor humidity into the equation and is therefore a useful alternative to temperature alone along the Gulf Coast, where high levels of summer humidity are expected.

Some contractors now use the wet bulb globe temperature (WBGT) – a metric utilized by the U.S. military for decades – that also factors in solar exposure and wind speed. In other words, WBGT is most relevant for people working in direct sunlight.

As actual, on-the-ground heat dangers vary with humidity, sun exposure and other factors, it’s recommended that contractors use heat index values to assess field conditions.

What Does OSHA Have to Say About Heat Safety?

OSHA doesn’t have heat-specific safety regulations on the books, but employers are still held to the General Duty Clause, which requires companies to identify and protect workers from any onsite hazards.

Employers can’t use “but there’s no OSHA heat safety standard” as an excuse, in other words.

The agency does have plenty of heat safety resources to draw from, though, including informational literature and tips for employers. This includes guidance on every part of the safety planning process, which can be extremely helpful for new contractors that don’t have an emergency action plan (EAP) in place.

Here are some practical tips for mitigating dangerous summer temperatures for every phase of the project.

Before the job begins: Create a Heat Safety Plan and Raise Awareness of Heat Hazards

Before mobilization, contractors should have a firm idea of the jobsite’s layout and where heat hazards are likely to emerge. For instance, if there’s a part of the site that’s exposed to dawn-to-dusk sunlight, it may be a good idea to avoid setting up any workstations in that area.

This is the kind of thinking that should be included in the project’s Emergency Action Plan (EAP). In fact, some contractors go a step further and draft a heat-specific safety plan. Given the extreme temperatures affecting some parts of the country (the south and southeast, most notably), heat-specific plans make a lot of sense. Each EAP should include the following:

  • The location and nature of any heat hazards on the jobsite. While trapped heat is usually a problem for interior work areas only, they can emerge on construction sites and other exterior work environments as well.
  • The location of any cooling stations or any air-conditioned areas. If heat illness does occur, moving the affected worker to a cool spot with shade is critical.
  • An inventory and location of all heat injury resources, such as cold packs, towels, and fluids.
  • A set of processes that specify what to do and who to contact should someone come down with heat illness.
  • The contact information for any nearby emergency medical institutions.

Once this plan is established, it must be communicated to all levels of leadership and to the workers themselves. Ideally, leadership and the crew would be involved in helping put together a heat safety plan. This will ensure that everyone on the team has a clear understanding of the company’s heat safety policies. Regular training, toolbox talks, and unscheduled drills are all worthy investments to ensure maximum heat safety awareness.

This training should also address what signs and symptoms of heat illness to look for, as other workers are likely to spot them first in their coworkers. They include:

  • Dizziness
  • Confusion
  • Slurred speech
  • Headache and muscle pain
  • Nausea and vomiting
  • Loss of consciousness

Invest in Tools That Monitor Heat Levels

If your workers can keep an eye on the temperature, they’ll be more aware of the heat and more likely to observe heat safety protocols.

The right tools are essential for jobsite safety, and when it comes to heat-related dangers, one such tool is a liquid crystal thermometer, as LCTs are compact, lightweight, and offer instant information about the temperature. LCTs can be encapsulated and scaled down to fit inside TWIC cards, which can be worn on a lanyard, kept in a pocket, or tossed in the toolbox. LCTs are accurate and can also include the company’s branding or additional heat safety information.

In this way, LCTs offer double advantages in safety and cost effectiveness, as they’re inexpensive to procure at volume and give workers a highly usable tool for remaining aware of the heat.

Get Workers Acclimated to the Heat and Set Up a Cooling Station

According to OSHA, about 75 percent of all heat-related deaths occur in the first week of the job. It takes time for the body to adjust to extreme heat stress, especially for people who aren’t accustomed to the climate or strenuous activity. To avoid overloading the team early on, OSHA recommends the 20 percent rule. The idea behind this is to slowly work up to full capacity in the sun over several days.

Assuming an 8-hour workday, using the 20 percent rule, workers should only spend one hour and 40 minutes (20 percent) in the sun during their first day on the project. They can spend the rest of the day working without heat stress. Every subsequent day, add another 20 percent in the sun until they’re up to full capacity. Some workers may need a bit longer to adjust, and it’s better to be safe than sorry, so allow for that time for adequate acclimation.

At the project’s outset, this is also the time to establish a cooling station. It should remain in the shade throughout the day and always have water available. Some contractors set up tents with circulating fans for additional heat relief, and if there’s an air-conditioned room they can access while cooling, even better.

Keep Safety Personnel on High Alert, Encourage Regular Breaks and Reduce Work Intensity in High Heat

During the peak of summer, there may be no relief from dangerously hot days. Where possible, shifting work to the evening or night hours is recommended, but noise ordinances may prevent this.

When work must be done during the day, being proactive is the rule. That means doing the following:

  • Enforcing regular water breaks. During high activity periods, giving workers a break every 15 minutes to drink fluids is recommended. Stick to water rather than caffeinated beverages.
  • Cycling work teams out of the sun regularly. If possible, cycling workers between sun-exposed and shaded workstations can reduce heat stress.
  • Occasionally taking worker vitals to spot early signs of heat stress. This should only be done by trained medical personnel.
  • Keeping the contact information for any medical authorities in an easily accessible place, so it can be instantly referenced in an emergency.

In general, the point is to remain on high alert while heat indexes are at their most punishing. The faster everyone responds to severe heat illness, the better the affected worker’s chances of fully recovering.

Summer Heat Can Be Fatal, but Employers Can Keep Their Team Safe with the Right Protective Measures

While summers have always been hot, recent summers have produced deadly levels of heat. For work crews, heat illnesses can emerge suddenly and may be severe, if not deadly. But with effective planning, emergency resources, cooling equipment, and a commitment to heat awareness, employers can keep their project sites and workers safe and heat injury free.