In fact, according to the CDC, an average of 43 U.S. workers die from heat-related illnesses each year, with thousands more suffering from serious injuries that lead to lost workdays, decreased productivity, and costly medical expenses. OSHA has made heat stress prevention a top enforcement priority, meaning companies that fail to protect their workers from heat hazards could face severe penalties.

But here’s the good news: Heat stress is 100% preventable! With the right protocols and PPE, you can protect your crew, stay compliant, and keep productivity high—even in extreme temperatures.

Top 5 Ways to Beat the Heat & Keep Workers Safe

1. Hydrate Like Your Life Depends On It—Because It Does!
By the time a worker feels thirsty, they’re already dehydrated. Drinking water every 15-20 minutes is critical to staying ahead of heat exhaustion. OSHA recommends cool water, but adding electrolyte-replenishing drinks helps replace lost sodium and minerals, preventing muscle cramps and fatigue.

Pro Tip: Set up hydration stations across the jobsite or facility to encourage frequent water intake. Make sure workers know the signs of dehydration: dark urine, dry mouth, and dizziness.

⏳ 2. Take Strategic Cool-Down Breaks
Rest isn’t a sign of weakness—it’s a safety necessity! During extreme heat, productivity actually improves when workers take frequent shaded or air-conditioned breaks. Heat stress can sneak up fast, and once the body overheats, it can be difficult to recover.

Pro Tip: If your jobsite lacks natural shade, consider setting up portable cooling tents or misting stations for quick cool-downs.

 3. Wear Smart, Not Just Safe—Use Cooling PPE!
Standard PPE is designed for protection, but when temperatures rise, heat stress PPE makes all the difference. Innovative cooling gear helps regulate body temperature and keep workers comfortable on the job.

Cooling vests: Lightweight, evaporative vests keep the core temperature down. Some even have ice pack inserts for extended cooling.
Cooling shoulder inserts: Designed to fit under safety vests and harnesses, these inserts provide targeted relief where heat builds up most.
Cooling hats and headbands: These wick away sweat and stay cool for hours when soaked in water.
Neck shades: These attach to hard hats, blocking sun exposure to the neck and reducing heat absorption.

Pro Tip: Choose moisture-wicking, breathable workwear to avoid heat buildup. Avoid dark colors that absorb heat and opt for lightweight, high-visibility gear to keep workers both safe and cool.

4. Ease Into the Heat—Acclimate New & Returning Workers
Heat stress is worse for workers who aren’t used to extreme temperatures. It takes 7-14 days for the body to adjust, so gradually increasing exposure is critical for new hires or workers returning from time off.

Pro Tip: Start with shorter shifts in high heat and gradually increase work time to allow the body to build tolerance. This process, known as heat acclimatization, can reduce the risk of heat stroke by up to 50%!

5. Recognize Heat Stress Early & Take Action FAST
Every second counts when a worker shows signs of heat stress. Supervisors and employees must be trained to recognize the warning signs and take immediate action.

Heat Stress Warning Signs:

⚠️ Heavy sweating
⚠️ Fatigue or dizziness
⚠️ Confusion or disorientation
⚠️ Muscle cramps
⚠️ Nausea or vomiting
⚠️ Rapid heart rate

If a worker shows these symptoms:

✅ Move them to a cool, shaded area
✅ Remove excess clothing and apply cooling towels
✅ Provide water or an electrolyte drink
✅ Seek medical attention if symptoms worsen

Pro Tip: OSHA recommends a buddy system in high-heat environments so workers can monitor each other for early signs of heat exhaustion.

Why Investing in Heat Stress PPE & Safety Training Matters

Beyond worker safety, heat stress prevention saves your company money. Consider this:

• Heat-related illnesses cost U.S. employers over $100 billion annually in lost productivity and medical expenses.
• OSHA is ramping up heat safety inspections and citations, and fines for non-compliance can be significant.
• Proper heat safety measures reduce absenteeism, increase efficiency, and improve morale.

By implementing a comprehensive heat safety program, including hydration stations, rest breaks, and cooling PPE, you protect your workforce AND your bottom line.