Introduction

Heat-related illnesses claim dozens of worker lives each year and send thousands more to emergency rooms. According to the Bureau of Labor Statistics, outdoor workers in construction, agriculture, and warehousing face the highest risk during summer months.

This guide walks you through building a comprehensive heat illness emergency response plan that protects your workforce and keeps you compliant with OSHA's heat illness prevention guidelines. You'll have a functional protocol ready to implement in about 2-3 hours.

36
Average Annual Heat-Related Worker Deaths
U.S. workplace fatalities from heat exposure (2011-2022)

Prerequisites

Before developing your heat illness response plan, gather the following resources and information:

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  • Include supervisors and designated first responders for each shift

  • Mark shaded rest areas, water stations, and cooling zones

  • Include nearest hospital addresses and 911 protocols for your area

  • Download from OSHA's Heat Illness Prevention Campaign website

  • NOAA's Heat Index Calculator or OSHA-NIOSH Heat Safety Tool app recommended

Step 1: Establish Recognition Protocols

Train all employees and supervisors to recognize the progressive signs of heat illness. Early detection prevents medical emergencies.

Critical Warning Signs
Confusion, slurred speech, loss of consciousness, or cessation of sweating indicate heat stroke—a life-threatening emergency requiring immediate 911 activation.
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  • Muscle spasms, usually in legs, arms, or abdomen during or after physical work

  • Heavy sweating, weakness, cold/pale/clammy skin, fast/weak pulse, nausea, fainting

  • High body temperature (103°F+), hot/red skin, rapid pulse, confusion, unconsciousness

  • Post laminated cards at all work stations showing symptoms and response actions

Step 2: Define Immediate Response Procedures

Your response protocol must outline specific actions based on illness severity. The CDC's heat stress guidelines recommend a tiered approach:

Response Tiers by Severity
Heat Cramps (Tier 1)
Stop activity, move to cool area, provide water, stretch affected muscles gently. Worker may resume work after symptoms resolve and 20-minute rest period.

Heat Exhaustion (Tier 2): Move worker to air-conditioned area immediately, apply cool wet cloths, provide small sips of water. Notify supervisor. If symptoms worsen or last longer than 30 minutes, seek medical attention.

Heat Stroke (Tier 3): Call 911 immediately. Move worker to cooler environment. Apply ice packs to neck, armpits, and groin. Do NOT give fluids. Stay with worker until emergency services arrive. :::

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  • Minimum one responder per 20 workers; ensure coverage during breaks

  • Ice packs, cool towels, fans, electrolyte drinks, and shade structures

  • Define exactly when to call 911 versus transport to clinic

Step 3: Build Your Communication Chain

Effective emergency response depends on rapid, clear communication. Establish a documented notification sequence that accounts for shift variations and remote work sites.

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  • Tier 1: Immediate supervisor → Tier 2: Safety manager → Tier 3: Site leadership

  • Ensure 24/7 coverage including weekends and holidays

  • Primary (radio/phone), secondary (text), and emergency backup procedures

  • Include on break room walls, equipment areas, and supervisor clipboards

Pro Tip
Program emergency contacts into company-issued phones or radios. In a crisis, workers shouldn't have to search for phone numbers.

Step 4: Implement Post-Incident Documentation

Thorough documentation protects your workers, satisfies OSHA recordkeeping requirements, and helps prevent future incidents. Every heat-related incident requires written records within 24 hours.

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  • Temperature, humidity, heat index, sun exposure, and ventilation at time of incident

  • Name, job task, time on shift, acclimatization status, and recent hydration

  • When symptoms appeared, progression, and all response actions taken with timestamps

  • First aid measures, EMS response, hospital transport, and medical recommendations

  • Identify contributing factors and corrective actions to prevent recurrence

Troubleshooting

Supervisors must have clear authority to remove symptomatic workers from heat exposure. Document the situation and enforce mandatory rest periods. Consider this a policy compliance issue requiring follow-up training.

Remote sites require enhanced preparation: additional cooling supplies, satellite communication devices, GPS coordinates for emergency services, and designated evacuation routes. Consider on-site EMT certification for remote crew leaders.

Translate all symptom cards and emergency procedures into workers' primary languages. Use visual diagrams and conduct hands-on training demonstrations. The OSHA-NIOSH Heat Safety Tool app is available in English and Spanish.

Maintain confidential records of workers on medications affecting heat tolerance (diuretics, antihistamines, certain blood pressure medications). Assign modified duties during high-heat periods and increase monitoring frequency.

Conclusion

You now have the framework for a comprehensive heat illness emergency response plan. Review and update your protocol annually before warm weather seasons, and conduct refresher training whenever you onboard new employees or supervisors.

Next Steps
Download the OSHA-NIOSH Heat Safety Tool for real-time heat index monitoring, and schedule quarterly drills to test your response procedures before actual emergencies occur.

Remember: effective heat illness prevention starts before the emergency. Combine this response plan with proactive measures—acclimatization programs, hydration schedules, and work-rest cycles—to protect your workforce throughout the heat season.