Working in hot conditions is not just uncomfortable, it can be dangerous. Heat stress can develop quickly and, if ignored, lead to serious illness or collapse on site. In Australia’s climate, heat exposure is a routine risk across warehouses, transport yards, loading docks and outdoor work areas, as well as inside vehicles and poorly ventilated buildings.
This toolbox talk outlines practical controls that help prevent heat related illness and protect everyone on site.
Heat illness can affect both indoor and outdoor workers. High temperatures, humidity, physical effort and restricted airflow all increase the risk. Early symptoms are easy to miss, particularly in fast-paced operations, making prevention and early action essential.
Key Controls
- Plan the Work
- Schedule heavy or repetitive tasks for cooler parts of the day where possible.
- Rotate tasks to reduce individual exposure to heat and physical strain.
- Allow additional time for rest during peak heat periods.
- Adjust productivity targets when temperatures rise, safety takes priority.
- Provide Environmental Controls
- Use fans, ventilation or air-conditioning in warehouses, vehicles and enclosed spaces.
- Improve airflow in loading docks, container areas and pick-and-pack zones.
- Provide shaded areas in yards and outdoor workspaces.
- Relocate tasks away from direct sun where practicable.
- Hydrate and Rest
- Drink cool water every 15 minutes, even if you are not thirsty.
- Take regular rest breaks in shaded or cooled areas.
- Avoid energy drinks or excessive caffeine, which can worsen dehydration.
- Report early signs of heat stress immediately—do not wait for symptoms to escalate.
- Clothing and PPE
- Wear breathable, lightweight workwear suitable for manual handling and operational tasks.
- Use sun protection where required: hats, long sleeves and sunscreen.
- Remove unnecessary layers when conditions become hot, where it is safe to do so.
- Ensure PPE does not trap excessive heat and is appropriate for the environment.
- Look Out for Each Other
- Use a buddy system, particularly for new starters, labour hire workers and those in physically demanding roles.
- Speak up if someone appears unwell, confused or unusually fatigued.
- Stop work and seek assistance if heat illness is suspected.
Signs of Heat Exhaustion
- Dizziness or light-headedness
- Headache
- Weakness or extreme fatigue
- Nausea or vomiting
- Excessive sweating
- Fast, weak pulse
Action: Move the person to a cool or shaded area. Have them rest, drink water and loosen tight clothing. Monitor closely and do not allow them to return to work until fully recovered.
Heat Stroke – Medical Emergency
- Red, hot, dry skin
- High body temperature
- Confusion, collapse or loss of consciousness
- Convulsions
- Strong, rapid pulse
- Little or no sweating
Action: Call emergency services immediately. Begin cooling at once using shade, cold packs or water. Do not leave the worker alone.
Daily Heat Safety Checklist
- Before starting work:
- Weather conditions checked
- Water, shade and cooling available
- Workload planned around heat
- PPE suitable for conditions
- During work:
- Drinking water every 15 minutes
- Breaks taken as scheduled
- Workers monitored for signs of heat stress
- Tasks adjusted if conditions worsen
If symptoms appear:
Stop. Cool down. Report. Get medical help if required.
Working in hot conditions may be unavoidable in logistics and supply chain operations, but heat illness is not. With proper planning, regular hydration, suitable workwear and a commitment to looking out for one another, serious incidents can be prevented and productivity maintained safely.
Badger supports safe worksites with PPE, sun protection and premium workwear designed to keep workers protected and comfortable, even when temperatures rise. Discover the full range: https://www.badgeraustralia.com.au/product-overview/
