Industrial environments can be hot and humid, posing a significant threat to worker safety and health. Heat stress, a condition caused by the body’s inability to cool itself effectively, can lead to debilitating and potentially life-threatening illnesses. Therefore, prioritizing heat stress prevention is paramount for any industrial operation.
This article outlines six key steps that industrial facilities can implement to create a safer and healthier work environment during hot weather.
Establish a Heat Illness Prevention Program (HIPP)
The first step is establishing a comprehensive Heat Illness Prevention Program (HIPP) as it will serve as the foundation for a successful heat stress mitigation strategy. It establishes a clear framework for identifying risks, implementing control measures, and ensuring worker awareness and preparedness.
The core components of a well-developed HIPP are risk assessment, medical monitoring, emergency response, and training. Risk assessment is the conducting of a thorough evaluation of the workplace to identify heat sources, strenuous activities, and environmental factors (temperature, humidity, air circulation) that contribute to heat stress. It is important to consider variations of the environmental factors across work areas and seasons. Develop a system for medically monitoring workers at risk for heat stress. This would involve pre-season screening for pre-existing health conditions, monitoring core body temperature during hot weather, and encouraging self-monitoring for symptoms. Establish a clear emergency action plan for responding to heat-related emergencies. This should include procedures for first aid, medical evacuation, and post-incident investigation. It is important to educate workers on the dangers of heat stress, how to recognize symptoms, and preventive measures they can take. It is equally important, if not more important, to train supervisors on identifying at-risk workers, monitoring work practices, and implementing control measures.
Engineering Controls to Reduce Heat Exposure
The second step is to implement engineering controls aimed at reducing the heat sources or modify the work environment to minimize heat buildup and worker exposure. Some practical strategies include ventilation, substitution, isolation, and work schedule adjustments. Ventilation improves air circulation through exhaust fans, air conditioners, or strategically placed open doorways and windows. Prioritize areas with high heat sources or intense physical activity. Whenever feasible, substitute high-heat generating equipment with more energy-efficient models. Automate tasks currently performed in hot environments. Isolation includes insulating hot pipes, ovens, surfaces, and other heat sources to prevent radiant heat emission into the work areas. Consider physical barriers to separate workers from heat sources. Work schedule adjustments include scheduling strenuous activities for cooler times of the day, if possible. Implement rotating shifts to minimize individual worker exposure to the heat.
Administrative Controls to Modify Work Practices
The third step is to implement administrative controls. When engineering controls are not feasible or insufficient, administrative controls provide alternative approaches to manage heat stress risk. Administrative controls include work-rest schedules, workload management, acclimatization, and hydration. Incorporating work-rest schedules into the workday when there is possible heat stress with regularly scheduled rest breaks in cool, shaded areas. The frequency and duration of breaks depend on the heat stress level and work intensity. Encourage workers to take advantage of breaks even if they don’t feel tired. Adjusting work practices to reduce physical exertion during hot weather includes simplifying the task, conducting the tasks for shorter periods of time by each employee, and assign lighter duties as needed. Encourage teamwork and buddy systems for heavy lifting or strenuous activities. Acclimatization is important though may be a challenge to attain. It is important to get the workers used to working in hot environments by gradually acclimatizing new or returning workers to hot environments by slowly increasing workload and wear time for protective clothing. This allows the body to adapt to the heat stress more effectively. An almost continuous effort is needed to provide readily accessible, cool drinking water throughout the workday. Encourage workers to drink fluids frequently, even if they don’t feel thirsty and encourage electrolyte-replacement beverages for extended work periods or heavy sweating.
Personal Protective Equipment (PPE) for Heat Stress Mitigation
The fourth step is to provide personal protective equipment (PPE) as the last line of defense against heat stress. However, it’s important to recognize that some PPE can actually contribute to heat stress if not chosen or used appropriately. Encourage workers to wear loose-fitting, lightweight, light-colored clothing made from breathable fabrics like cotton. This allows for better air circulation and sweat evaporation. Provide hats with wide brims and sunglasses to shield workers from direct sunlight and its heat load. Cooling vests or bandanas moistened with cool water provide localized cooling and can help regulate body temperature though need to be remoistened with cold water often.
Worker Monitoring
The fifth step in effective heat stress prevention hinges on continuous monitoring of workers and the work environment. Developing and implementing a system for monitoring environmental conditions (temperature, humidity, and air movement) and worker core body temperature during hot weather along with the activation of alerts to the workers and supervisors when limits have been met or are being exceeded. By regularly monitoring workers, especially those at higher risk due to strenuous activity, pre-existing health conditions, or medication use, it is more likely to identify signs of heat stress early and allows for prompt intervention before a worker’s condition worsens. Monitoring data on worker core temperature, environmental conditions, and hydration levels helps assess the overall heat stress risk in real-time. This allows supervisors to adjust work practices (like extending rest breaks) or implement additional control measures as needed. Monitoring data on worker responses to heat exposure can inform management about needed adjustments to acclimatization programs. By gradually increasing workload and wear time for PPE based on individual tolerance, workers can adapt more effectively to hot environments.
Maintaining Open Communication Channels
The sixth step is open communication between workers, supervisors, and management. Open communication channels empower workers to report early signs and symptoms of heat stress (headache, nausea, dizziness) without fear of reprimand. This allows for early intervention and prevents further health complications. Open communication allows for feedback on training materials and program effectiveness. Workers can share real-world experiences and concerns, allowing for targeted training revisions and improved knowledge retention. Open communication fosters a culture of safety where workers feel comfortable raising concerns about heat stress risks, suggesting improvements to control measures, or requesting modifications to work practices. This collaborative approach strengthens the overall heat stress prevention program.
Additional Ideas
A few additional ideas to implement in the heat prevention effort in an industrial environment include having Supervisors conducting regular check-ins with workers throughout the shift, observing for signs of heat stress and inquiring about hydration and comfort levels. Establish anonymous reporting systems for workers to report heat stress concerns or unsafe work practices without fear of retaliation. Conduct regular surveys to assess worker understanding of heat stress risks, their comfort levels, and their suggestions for improvement.
ANSI/ASSP A10.50 standard
A recently released standard that will be very useful is the ANSI/ASSP A10.50, Heat Stress Management in Construction and Demolition Operations. It offers guidance on how to protect workers from the health effects of high heat conditions. The standard provides guidance, charts, tables, checklists, and examples of the elements within a Heat Injury Prevention Program that includes engineering and administrative controls, acclimatization, emergency response planning, and specific training for workers and Supervisors. Even though the name and scope of the standard focuses on construction and demolitions, the guidance can be easily adapted to protect workers in an industrial environment.
Summary
Implementing the 6 steps listed above and using the ANSI/ASSP A10.50 standard on heat injury prevention along with other readily available information on the OSHA and NIOSH websites will protect workers from excessive exposure to heat in the work environment preventing heat stress and reducing the likelihood of workers experiencing heat illnesses.
The information in this article was compiled using artificial intelligence (AI) and edited by the author.
For more information and/or assistance, contact:
Wayne Vanderhoof CSP, CIT
Sr. Consultant/President
RJR Safety Inc.