Too Hot to Handle? How to Stay Safe When Working in Extreme Heat

Heat isn’t just uncomfortable, it’s dangerous

Every year, dozens of workers lose their lives to heat exposure, and thousands more are hit with heat-related illnesses. While construction sites are notorious for extreme temperatures, no workplace is completely safe from the risks of overheating

Your body is a temperature-regulating machine, but it has its limits

Have you heard the story of the frog in the slowly boiling pot? The water heats up gradually, and the frog doesn’t notice until it’s too late. That’s exactly how heat stress works on the job. One minute, you’re pushing through, and the next, your body is waving the white flag

High temperatures, humidity, and direct sun exposure push your body to the edge. Add intense labor or hot equipment, and the risks spike even higher

What makes heat stress worse?

• Environmental conditions: Hot air, high humidity, poor airflow, or tight spaces like warehouses and factory floors
• Task-specific risks: Strenuous labor, welding, working with heat-producing machines, or asphalt and roofing work
• Individual factors: Physical fitness, weight, age, medications, past heat-related incidents
• Controllable factors: Hydration, acclimatization, PPE, and appropriate clothing

Rooftops soak up sunlight, asphalt radiates heat, and confined spaces turn into ovens. Even indoor workplaces with poor ventilation can be just as hazardous. Heat exposure doesn’t wait for summer, it can be a problem any time of year. The key? Preparation

Heat-related illnesses don’t discriminate

Heat hazards aren’t exclusive to construction or agriculture. Any worker exposed to high temperatures, whether inside or outside, is at risk

Common heat-related illnesses

• Heat stroke: The most dangerous heat illness. Symptoms include confusion, seizures, slurred speech, and loss of consciousness. The body overheats and can’t cool down. This is a medical emergency
• Heat exhaustion: Heavy sweating, dizziness, nausea, and muscle weakness. If untreated, it can escalate to heat stroke
• Rhabdomyolysis: Excessive exertion in heat causes muscle breakdown, which can lead to severe kidney damage
• Heat syncope: Fainting or dizziness caused by standing too long or sudden movement in extreme heat
• Heat cramps: Painful muscle spasms due to salt depletion from heavy sweating
• Heat rash and fatigue: Skin irritation and overall exhaustion from long exposure to hot conditions

Every one of these conditions is predictable and preventable. With the right training, monitoring, and response, workplaces can drastically reduce heat-related risks

First aid and quick action can save lives

Employer responsibilities

OSHA requires employers to train workers on heat hazards and provide the necessary protections. A Job Hazard Analysis (JHA) should identify tasks that increase heat exposure, like outdoor labor or working near high-temperature machinery

Preventing heat stress

• Mandatory breaks: Regular rest in shaded or cool areas helps the body recover
• Environmental monitoring: Use tools to track temperature and humidity to adjust work schedules accordingly
• Hydration: Encourage workers to drink cool (not ice-cold) water frequently
• Heat acclimatization: Gradually introduce workers to hot environments with shorter shifts and lighter workloads
• PPE adjustments: Ensure protective gear doesn’t trap excess heat. If necessary, look for alternatives that allow better airflow

Emergency response

• Cool the worker immediately: Move them to a shaded or air-conditioned area, apply cold packs or water, and fan them
• Call for help: If symptoms point to heat stroke, call 911 immediately
• Monitor their condition: Keep them calm, encourage hydration, and do not leave them alone

A solid heat illness prevention program saves lives

A workplace safety plan should include:

• Training: Employees should know the signs of heat stress and how to prevent it
• Acclimatization: Workers need time to adjust to heat, especially after time off
• Environmental tracking: Tools like OSHA’s Heat Safety Tool app help assess risk levels
• Emergency protocols: Clearly outline what to do if heat-related illness strikes
• Access to resources: OSHA’s On-Site Consultation Program offers free guidance for heat safety improvements

Creating a culture of heat safety ensures workers stay healthy and productive

Employers have a duty to protect workers from heat hazards

Workers have the right to report unsafe conditions, ask for better protections, and receive training in a language they understand. Heat stress isn’t about “toughing it out”, it’s a legitimate hazard that can have serious, even fatal, consequences. Recognizing the risks and taking proactive measures makes all the difference

Expand your knowledge with heat stress training

This course introduces Heat Stress: Employee Safety, but there’s more to learn. For a deeper dive into heat hazards, prevention strategies, and emergency responses, enroll in our Heat Stress: Employee Safety in Construction Training Course

References

• Occupational Safety and Health Administration (OSHA) – Heat Exposure
• National Institute for Occupational Safety and Health (NIOSH) – Heat Stress Recommendations
• Bureau of Labor Statistics (BLS) – Injuries, Illnesses, and Fatalities