Extreme Temperature Hazards In The Workplace & Controls

The importance of addressing extreme temperature hazards in the workplace cannot be overstated. Excessive high and low temperatures present serious health and safety risks, impacting employees’ well-being, productivity, and morale and potentially leading to significant liabilities for employers.

Working in extreme heat or cold can pose many health risks, ranging from discomfort to serious life-threatening conditions. Heat can induce heatstroke, dehydration, and fatigue, while cold can cause frostbite, hypothermia, and impaired motor skills. Moreover, these temperature extremes can exacerbate health conditions like cardiovascular and respiratory diseases.

Besides health hazards, extreme temperatures can also affect employees’ cognitive functions and overall performance, potentially leading to errors, reduced productivity, and increased accident rates. In addition, equipment and materials may also be adversely affected by extreme temperatures, compromising their reliability and lifespan.

Ignoring these risks not only endangers the employees but also poses a considerable threat to the operational efficiency of an organization. Therefore, implementing appropriate controls and preventive measures is paramount in ensuring a safe, healthy, and productive work environment while complying with occupational health and safety regulations.

Heat Hazards And Control Measures

Types of Extreme Temperatures in the Workplace

Employees may encounter various extreme temperature conditions in workplaces across the globe. The two primary categories are extreme heat and extreme cold, each with unique risks and challenges.

1. Extreme Heat

Extreme heat conditions are common in several industries. For instance, workers in foundries and steel mills are regularly exposed to extreme heat due to the nature of the materials they work with. Other professions often facing high heat conditions include firefighters, bakers, glass manufacturers, and outdoor workers in regions with high summer temperatures, such as construction workers, agricultural workers, and road maintenance crews. High heat conditions may also exist in commercial kitchens, laundries, power plants, and boiler rooms.

2. Extreme Cold

Workers can also be exposed to extremely cold temperatures on the opposite end of the spectrum. This can occur in both outdoor and indoor settings. Outdoor occupations exposed to extreme cold typically include those working in northern or polar regions, such as fishermen, miners, construction workers, and utility repair workers during winter. Indoor exposure to extreme cold is common in industries such as meat, dairy, and frozen food processing and storage, as well as those working in refrigeration units, cold storage facilities, and certain scientific environments requiring low-temperature conditions.

Regardless of the specific type of extreme temperature, all these workers require special precautions to ensure their health and safety. Employers in these industries must be particularly aware of the risks and implement appropriate controls and interventions to manage the occupational hazards of extreme temperature exposure.

Hazards Associated with Extreme Heat

Working in extreme heat conditions significantly threatens workers’ health and safety. The impact of heat is not confined to discomfort; it can trigger a range of heat-related illnesses, including heat rash, heat cramps, heat syncope (fainting), heat exhaustion, and the most severe—heatstroke.

  • Heat Rash: Also known as prickly heat, this condition is characterized by itchy skin and a rash of small red bumps. It happens due to excessive sweating that leads to clogged sweat ducts.
  • Heat Cramps: Heat cramps are painful, involuntary muscle spasms that usually occur during heavy exercise in hot environments. Sweating leads to losing body salts and fluids, which can result in cramping.
  • Heat Syncope: Heat fainting is a brief loss of consciousness due to low blood pressure caused by dehydration and standing or rising suddenly in a hot environment.
  • Heat Exhaustion: This serious condition can develop from prolonged exposure to high temperatures and inadequate or unbalanced replacement of fluids. Symptoms include heavy sweating, rapid pulse, dizziness, fatigue, cool and moist skin with goosebumps in the heat, and muscle cramps.
  • Heatstroke: This medical emergency occurs when the body’s temperature regulation fails, leading to a dangerously high body temperature. Symptoms include high body temperature, altered mental state or behaviour, nausea and vomiting, flushed skin, rapid breathing, racing heart rate, and headache. Untreated heatstroke can quickly damage your brain, heart, kidneys, and muscles.

Extreme heat conditions can also impact worker productivity and safety significantly. Heat can impair concentration, leading to careless errors and accidents. Physical performance, especially strength, can also be reduced. Furthermore, prolonged exposure to excessive heat can lead to dehydration, further exacerbating fatigue and cognitive impairment. Workers may also experience a decreased ability to self-pace their work, leading to overexertion and potential heat-related illnesses.

In industries such as construction or agriculture, high temperatures can also increase the risk of accidents due to sweaty palms, fogged-up safety glasses, and dizziness. Prolonged exposure can also lead to serious long-term health issues, including respiratory difficulties, kidney disorders, cardiovascular disease, and skin cancer.

Temperature Hazards

Hazards Associated with Extreme Cold

Working in extreme cold conditions, whether indoors or outdoors, carries serious health risks and potential hazards. The primary health threats include frostbite, hypothermia, and a general condition known as cold stress.

  • Frostbite: Frostbite occurs when the skin and the tissue beneath freeze due to exposure to very low temperatures. It most commonly affects extremities like fingers, toes, nose, ears, cheeks, and chin. Early signs include a prickling feeling and reduced blood flow, followed by numbness. The affected area may appear white or greyish-yellow and feel unusually firm or waxy.
  • Hypothermia is a medical emergency when your body loses heat faster than it can produce heat, causing a dangerously low body temperature. Symptoms begin with shivering and fatigue and progress to confusion, memory loss, slurred speech, drowsiness, and in severe cases, loss of consciousness.
  • Cold Stress: Cold stress occurs when the skin and internal body temperatures drop. It can lead to uncontrolled shivering, poor coordination, fatigue, and confusion. In severe cases, it can completely shut down the body’s systems.

Extreme cold affects not only the health of workers but also their productivity and safety. Like extreme heat, extreme cold can impact cognitive functions, slowing reaction times, impairing judgement and increasing the risk of errors and accidents. Cold can also stiffen muscles and joints, limiting manual dexterity and mobility and making certain tasks more difficult and hazardous.

In addition, the use of bulky winter clothing and equipment can inhibit movement and visibility, posing additional safety risks. Equipment used in the workplace can also malfunction in cold conditions, leading to further potential hazards.

Risk Factors and Vulnerable Workers

Several risk factors can heighten workers’ susceptibility to extreme temperature hazards, making it critical for employers to identify and consider them in their occupational health and safety strategies.

  • Age: Older workers may be more susceptible to extreme temperatures, especially heat, due to the physiological changes that come with aging. These changes can include a decreased ability to sweat and a slower metabolic rate, making it harder for the body to regulate its temperature.
  • Pre-existing Medical Conditions: Certain health conditions can exacerbate the effects of extreme temperatures. For example, individuals with heart conditions, diabetes, high blood pressure, or respiratory diseases may worsen their symptoms in extreme heat or cold.
  • Medications: Some medications can interfere with the body’s ability to regulate temperature or increase dehydration risk, making individuals more vulnerable to temperature extremes. Examples include diuretics, antihistamines, blood pressure medications, and certain psychiatric medications.
  • Physical Fitness: Workers with low physical fitness levels or obesity may have difficulty coping with temperature extremes. The body’s ability to regulate temperature is closely linked to physical health and fitness.
  • Lack of Acclimatization: Workers not used to working in extreme temperatures, either hot or cold, are particularly at risk. Acclimatization is a process of gradual adaptation to changes in the environment, and without it, the body can be shocked by sudden exposure to extreme conditions.

Inadequate Hydration or Nutrition: Dehydration can quickly exacerbate the effects of extreme heat and also affect the body’s response to cold. Similarly, inadequate nutrition can reduce the body’s ability to withstand or adapt to temperature extremes.

High Temperature Hazards

Controls and Preventive Measures

Inevitably, the first course of action is to eliminate the need for workers to enter the extreme temperature environment (e.g. by automation a process). Where this cannot be done, the environment might be regulated to reduce the temperature extremes (e.g. heating a cold workplace to more reasonable temperatures). If these options are not possible, then other controls might be:

For A Hot Environment:

  • Provide good workplace ventilation – moving air has a cooling effect.
  • Insulate heat sources – by lagging hot pipes.
  • Shield heat sources – to control radiant heat and prevent contact burns.
  • Provide cool refuges – where workers can escape the heat.
  • Provide easy access to drinking water or isotonic drinks.
  • Provide frequent breaks and job rotation.
  • Provide appropriate clothing for use in the hot work environment, but consideration must be given to other workplace hazards.

For A Cold Environment:

  • Prevent or protect workers from draughts.
  • Shield/lag on extremely cold surfaces.
  • Provide warm refuges – where workers can warm up.
  • Provide PPE – such as insulated jackets, trousers, boots, balaclavas, etc.
  • Provide frequent breaks and job rotation.
  • Provide easy access to hot food and drinks.
  • Scrape, salt, or grit icy floors.

Additional Control Measures

Managing extreme temperature hazards effectively requires a combination of engineering controls, administrative controls, and the use of personal protective equipment (PPE). These measures can significantly reduce the risks of working in extreme heat or cold conditions.

  • Engineering Controls: These involve modifying the work environment to reduce exposure to extreme temperatures. This could involve installing cooling fans, air conditioning, or ventilation systems to reduce heat and humidity in hot environments. Heaters, insulation, and windbreaks can help keep temperatures safer in cold environments. Moreover, shielding and other measures can reduce radiant heat from hot surfaces, and refrigeration units can be insulated to reduce cold leakage.
  • Administrative Controls involve changing work practices and policies to reduce or prevent exposures. This could include implementing work/rest cycles, allowing workers to acclimate to extreme temperatures gradually, and scheduling physically demanding tasks during the cooler parts of the day in hot or warmer parts in cold environments. Employers can also ensure appropriate rest, recovery, and rehydration facilities and that workers can access water and hot drinks in hot and cold conditions.
  • Personal Protective Equipment (PPE): In extreme heat, PPE may include lightweight, breathable clothing, cooling vests, and neck shades. PPE might include thermal clothing, gloves, and hats in extreme cold. It’s crucial that PPE is designed to accommodate the physical demands of the job and doesn’t impede movement or safety.

Regardless of the specific measures used, education is key to their effectiveness. Employers should train all employees to help them understand the hazards associated with extreme temperatures, recognize the signs and symptoms of heat or cold stress, and understand how to prevent and respond to these conditions. This should also include instructions on correctly using and maintaining any relevant PPE.

Extreme Temperature Hazards

Emergency Preparedness

An integral part of managing extreme temperature hazards in the workplace is having a well-developed emergency response plan for events such as heatwaves or sudden cold snaps. These plans should be specifically tailored to the hazards and risks faced by the organization and should be designed to respond swiftly and effectively to protect workers.

  • Emergency Response Plan: This plan should detail the specific actions to take during extreme temperature events. It should include steps to monitor weather conditions, adjust work schedules, and ensure access to appropriate resources like water or warm drinks. The plan should also outline the procedures for responding to heat or cold-related illnesses, including first aid measures and emergency contacts.
  • Regular Drills: Regular emergency drills are important to ensure that everyone knows their role in the event of an extreme temperature event. Drills can help identify gaps or weaknesses in the plan, allowing for continuous improvement.
  • Communication Systems: A reliable system for communicating warnings, instructions, and updates is crucial during extreme temperatures. This system could include sirens, PA systems, two-way radios, or text alerts.
  • Designated Shelters or Warm-Up Areas: In the event of a heatwave, shaded areas or air-conditioned spaces can provide crucial relief for workers. In cold conditions, heated shelters or indoor areas should be provided for workers to warm up during breaks.

Supervisors, managers, and coworkers are paramount in recognizing and responding to heat or cold-related emergencies. They should be trained to recognize the signs of heat or cold-related illnesses and understand how to respond swiftly and effectively. Regular training and refreshers can ensure that this crucial knowledge is updated.


In conclusion, the challenge of extreme temperature hazards in the workplace is multi-faceted and requires a comprehensive approach to mitigate effectively. Planning, preparation, and a proactive attitude towards safety make it possible to protect workers and maintain productivity even under extreme temperature conditions. Employers and employees must work together to foster a culture prioritising safety and health, ensuring that extreme temperatures are managed effectively, and the workforce remains protected.