Warehouse Safety in the Summer: Beat the Heat and Protect Your People

Introduction to Occupational Heat Stress

As temperatures rise, so do the risks, especially for people working in hot environments or without air conditioning. These include warehouse employees and field service teams. At Carolina Handling, the Environmental Health & Safety Team takes essential steps to educate associates and implement best practices to prevent heat-related illnesses before they happen.   

Our associates are encouraged to be weather-aware as they plan their workdays. They are taught the signs of heat stress and how to take precautions to avoid heat illness and dehydration. 

“Planning and preparation will allow the associate to take the proper preventative measures to avoid at-risk conditions. That includes working during the cooler times of day, working in shade or indoors, being prepared with plenty of water for hydration and dressing appropriately for the weather conditions by wearing lighter clothing,” said Mark Hernadez, Senior Environmental Health & Safety Manager at Carolina Handling.

“At Carolina Handling, we always put our people first, ensuring they have the information and knowledge needed to plan, prepare and protect themselves. We also set the expectations and provide the resources necessary to follow those measures,” Hernandez said.

This guide covers heat safety practices tailored for warehouse and industrial environments. It emphasizes practical heat protections, from hydration schedules and acclimatization plans to the importance of access to shade and cooling gear. The goal is to ensure associates stay safe and productive in high-temperature environments.

What is Heat Stress?

Heat stress occurs when the body’s means of controlling its internal temperature begin to fail. Beyond discomfort, heat stress poses serious safety risks. At 99.7°F (37.6°C), the body is already in distress, and heat stress has started to affect it. At 104°F (40°C), the risk becomes life-threatening. Just 30 minutes at this level can cause cellular damage to the brain or even death. 

Here are some personal risk factors that put people at risk of heat stress:

• Older age
• Overweight
• Have pre-existing medical conditions such as heart disease or high blood pressure
• Take certain medications that don’t react well to extreme heat

Here are some environmental risk factors that make people at greater risk of heat stress:

• High temperatures
• Humidity
• Direct sunlight
• Limited air movement
• Hot equipment
• Heat-reflecting surfaces like concrete and asphalt
• Reflected heat from water or objects
• Clothing/PPE choices

Recognizing the Symptoms

Heat-Related Illnesses (HRIs):

• Heat Rash: Occurs when sweat ducts become clogged, and sweat can’t get to the skin’s surface
  • Symptoms: Red, blister-like bumps, itching
  • Treatment: Keep the skin dry and rest in a cool place
• Heat Cramps: Occur when salt and moisture levels are depleted through perspiration
  • Symptoms: Painful spasms, usually in the legs or abdomen
  • Treatment: Move to a cool and shaded area, use a cold compress and drink plenty of fluids
• Heat Exhaustion: Occurs due to prolonged exposure to high temperatures and inadequate hydration, which causes body temperatures to rise
  • Symptoms: Headaches, weakness, change of mood, feeling sick, pale and/or clammy skin
  • Treatment: Move to a cool and shaded area, use a cold compress and drink plenty of fluids
• Heat Stroke: Happens when the body is not able to control its core body temperature
  • Symptoms: Vomiting, confusion, pale skin and nausea
  • Treatment: Immediately seek medical attention

Hot Weather Impacts Us All Differently

If you are struggling or feeling distressed, it’s essential to talk with your team leader or manager immediately. Hernandez said Carolina Handling has developed an internal safety alert to educate new associates on the risk factors and control measures for preventing heat illness.

“Managers and team leaders set the expectation for planning and use of company resources to facilitate the protective measures for our associates during the summer months. They also monitor working conditions, personal health conditions and work-related conditions to ensure our associates are not at risk or overexposed to heat stress-related conditions,” Hernandez said.

Undergoing a medical examination before starting a new job can provide you with valuable health information that could be critical for your well-being as you begin your role.

“People with personal health conditions should consider a medical evaluation or physical to ensure they can meet the job demands in working conditions that present heat stress on their body. Getting acclimated at the beginning of the season is very important,” Hernandez said.

Hernandez said Carolina Handling associates are required to receive safety alert refresher training every three years. In addition to that training, Hernandez said awareness is raised at the beginning of the summer season to remind associates of the resources provided and the measures to take to protect themselves from heat stress. He said when associates are not feeling well, they have the responsibility to notify the team leader or manager, and in some cases, the customer, if there is a need for immediate assistance.

“Every associate has the personal responsibility to know their health condition, limits and take the appropriate measures to protect themselves when working in at-risk environments. All associates have the stop work authority to call a timeout to request assistance or take additional breaks when needed,” Hernandez said.

Legal Framework and Heat Laws

In June and July 2025, OSHA hosted a virtual public hearing on its proposed rule titled Heat Injury and Illness Prevention in Outdoor and Indoor Work Settings. OSHA officials said the rule would more clearly set forth employer obligations and the measures necessary to protect employees effectively from hazardous heat. The programmatic standard, which would require employers to create a plan to evaluate and control heat hazards in their workplace, would apply to all employers conducting outdoor and indoor work in all general industry, construction, maritime and agriculture sectors where OSHA has jurisdiction, with some exceptions.

According to OSHA, many states run their own OSHA-approved State Plans, and some states have standards for heat exposure.

Here is an overview of the Plans across Carolina Handling’s territory, according to OSHA:

• North Carolina: North Carolina operates an OSHA-approved State Plan covering most private-sector workers and all state and local government workers.
• South Carolina: South Carolina operates an OSHA-approved State Plan covering most private-sector workers and all state and local government workers.
• Georgia: Georgia is under federal OSHA jurisdiction, which covers most private-sector workers within the state. Federal OSHA does not cover state and local government workers.
• Alabama: Alabama is under federal OSHA jurisdiction, which covers most private-sector workers within the state. Federal OSHA does not cover state and local government workers.
• Florida: Florida is under federal OSHA jurisdiction, which covers most private-sector workers within the state. Federal OSHA does not cover state and local government workers.

Workers and supervisors are encouraged to use the OSHA-NIOSH Heat Safety Tool. According to OSHA’s website, the App can calculate a worksite's heat index and display a risk level for outdoor workers. It also offers reminders about protective measures to take when working in the heat. 

Implementing a Heat Stress Prevention Program

The Environmental Health & Safety Team at Carolina Handling highlights the importance of proactive planning to ensure the safety of employees working in hot conditions. Preventative measures include giving associates time to acclimate to the heat through repeated, gradual exposure.    

“By being gradually exposed to work in hot conditions, a body develops greater tolerance for the heat,” Hernandez said. He said most people can acclimate within 4-14 days when performing regular work for at least two hours per day in the heat. 

“However, it’s important to note that it’s difficult to predict when someone will be affected by the heat,” Hernandez said.

Preventive Measures

Team members are encouraged to evaluate their work tasks for possible heat risks and create a plan to implement suitable protective measures to prevent heat-related illnesses.

These measures should include:

• Drink enough water:
  • Associates must have access to a sufficient water supply at the start of the shift and replenish as needed.
  • When working in moderately hot environments with a heat index ranging from 80 to 90°F, employees should consume approximately one 8-ounce cup of water every 15 to 20 minutes.
• Have access to shade:
  • Associates will be provided with access to shade through the use of indoor shops, vehicles and other shaded environments to minimize direct exposure to the sun.
• Control measures:
  • Each team member operating in hot environments where the heat index exceeds 90°F will take essential steps to manage common environmental risk factors, such as air temperature, humidity, heat from radiant sources, and air circulation.
• Examples of control measures include:
  • Taking breaks in air-conditioned spaces, including service vans.
  • Scheduling work during cooler hours, when possible.
  • Planning for additional rest and water breaks when necessary.
  • Wearing lightweight, loose-fitting, breathable clothing. Avoid unnecessary PPE that adds a burden or heat stress to the body.
  • Use neck gaiters, fans and cooling towels to provide additional cooling for the body.  
  • Carry cell phones or other means of communication to ensure emergency services can be called if needed.
• Use a buddy system:
  • The CDC recommends using a buddy system, where workers look out for each other. 
  • Often, it is a coworker who first notices signs of heat stress in another employee, according to CDC officials.

“Carolina Handling has the flexibility to adjust working schedules at our branch locations during the hotter summer months. Field service technicians have the flexibility to start their days earlier during the cooler part of the day, depending on the customer’s hours of operation,” Hernandez said.

“The most effective measures involve the associate planning their day to ensure they have access to plenty of water, shaded environments to take adequate breaks and working during the cooler parts of the day,” Hernandez said.

Hydration Reminders

Conclusion: A Culture of Care in Every Degree

As summer temperatures climb, so does the responsibility to protect the people who keep operations moving. We understand that when you protect your team, you protect your business.

“Taking care of our people is what makes us the best in our industry. If our people are not well, safe, or productive, we cannot effectively run our business and support our customers. Carolina Handling leads by example when implementing heat illness prevention measures. We can help our customers in order to provide additional safety guidance,” Hernandez said.

At Carolina Handling, we recognize prevention as the most powerful form of protection. Focusing on proactive planning, training and real-time assistance gives team members the knowledge, tools and confidence they need to handle hot environments safely. From hydration and acclimatization protocols to shade access and heat risk assessments, our team is deeply committed to minimizing risk and maximizing well-being.

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