To operate safely in hot or cold conditions, workers “need to trust what they’re wearing,” says Derek Sang, senior technical training manager for Bulwark Protection and Workrite Fire Service.
This can be a challenge for safety professionals, who need to provide workers with personal protective equipment that not only allows them to do their jobs effectively but also keeps them comfortable, visible and protected from the elements.
For example, a high-visibility hoodie that offers protection against cold winds may also be bulky and restrict the wearer’s movements. And safety pros have long known that workers will simply remove or not use PPE that creates more of a problem than a solution.
To help safety pros address these challenges, some representatives from PPE manufacturers recently weighed in on this question:
What are some of the biggest challenges safety pros face when it comes to protecting workers from extreme temperatures?
Here’s what Sang and other industry experts had to say:
When choosing protective workwear, many safety experts think of the basics: equipment that helps employees withstand falls, impacts and loose debris. However, as extreme temperatures become increasingly commonplace, temperature regulation should also be a top priority. Extreme cold or heat can not only make the workplace uncomfortable, but unsafe – exposing workers to dangers ranging from dehydration to frostbite. In cold weather, extremities like toes are often the first to be impacted. For workers who spend long days on their feet, this can be a major challenge. Insulated boots are essential for keeping feet warm. Sweat-wicking, breathable material is also important here; while sweat may not seem like a factor in cold weather, even a small amount of excess moisture can worsen the risk of numbness, pain and frostbite in the toes. On the other end of the spectrum, improper boots can trap heat during warm weather spells. Prolonged exposure to high temperatures increases the risk of heatstroke, as well as blisters and skin irritation that can keep workers off their feet. Boots designed with lightweight, breathable materials can help keep feet dry and cool, reducing discomfort and preventing more serious health risks.
– Tito Warren, President, Global Industrial, Red Wing Shoes
Protecting workers from extreme cold comes with unique challenges for safety professionals. The biggest concern is achieving the right balance between warmth, comfort and mobility. Cold stress affects individuals differently – factors such as physical fitness, hydration and body type can influence how workers tolerate cold conditions. This means one solution may not meet everyone’s needs. Layering is often the most effective strategy, but garments must do more than trap heat. They need to regulate temperature, manage moisture and stay dry – because dryness is key to staying warm. At the same time, safety pros must avoid outfitting workers in clothing that is bulky or restrictive. Limited mobility, reduced dexterity or materials that stiffen in low temperatures all can create new hazards on the job. The ideal solution lies in versatile, multifunctional garments that deliver warmth without bulk and adapt to different activity levels and environments. By prioritizing protection, breathability and ease of movement, safety pros can help ensure workers remain safe, comfortable and productive – even in the most challenging cold-weather conditions.
– Samantha Bigner, Product Marketing Specialist, Protective Industrial Products
Safety professionals face many challenges when it comes to keeping workers safe in extreme temperatures, and choosing the proper PPE is a big part of the solution. Heat and cold stress can be serious issues – extreme heat can lead to dehydration, heat exhaustion or even heatstroke, while extreme cold increases the risk of frostbite and hypothermia. For working in hot environments, PPE such as cooling vests; moisture-wicking clothing; ventilated hard hats; evaporative cooling towels; and lightweight, breathable gloves and boots can significantly improve worker comfort and reduce body heat buildup. In cold conditions, insulated jackets; thermal gloves; balaclavas; faceshields; and insulated, slip-resistant boots help protect against freezing temperatures. Layered clothing systems made from moisture-wicking and thermal fabrics are beneficial for maintaining body temperature while preventing sweat from freezing. It’s also important to monitor conditions closely. Tools including wet bulb globe temperature monitors and heat index measurements give a more accurate picture of heat risk, while thermal sensors can help assess cold-stress hazards. Finally, making sure workers know how to spot the early signs of heat and cold stress, combined with proper PPE and emergency drills, goes a long way toward keeping everyone safe.
– Ray Chishti, Senior EHS Editor, J. J. Keller & Associates Inc.
The biggest challenges safety managers face in reducing risks from heat stress or hypothermia are keeping workers both visible and safe while meeting American National Standards Institute 107 high-visibility requirements. In hot conditions, layering is a major issue. Workers often wear a high-vis vest over other garments, which traps heat, restricts airflow, and increases the risk of dehydration and fatigue. In cold weather, the opposite occurs – bulky outerwear covers compliant gear, reducing visibility around equipment and vehicle hazards. A strong mitigation plan starts with climate-appropriate garment selection. In heat, choose lightweight, breathable ANSI 107-compliant T-shirts or vests with moisture-wicking fabrics and mesh panels to increase airflow. Provide cooling breaks, hydration and shade. Train crews to avoid unnecessary layering beneath vests. In extreme cold, supply ANSI 107-compliant outerwear so visibility isn’t compromised as layers are added. Establish layering protocols that adapt to conditions and train teams to recognize how extreme heat or cold affects workers. Ultimately, the goal is eliminating the choice between comfort and compliance. By anticipating environmental challenges, specifying the right garments and reinforcing training, safety managers can keep workers visible, protected and productive – no matter the temperature.
– Sandra Hanna, Vice President of Marketing and Product Development, Kishigo
One of the biggest challenges with managing extreme temperatures in the arc-flash world is balancing the need to protect against one hazard – large arc flashes – without exacerbating the risk of another hazard: heat stress. According to OSHA, the Centers for Disease Control and Prevention, NIOSH and others, single-layer, breathable apparel doesn’t contribute to heat stress, whether it’s non-flame resistant, FR, arc rated, short sleeve or long sleeve. Long sleeves are actually safer for heat stress because the sun on skin is a radiant heat load. However, multiple layers do contribute to heat stress because they can adversely affect the body’s ability to dissipate heat. This creates an inherent challenge with Cat 3 and Cat 4 PPE, which are usually multiple-layer and typically worn over a base layer. It is thus critical that all other available measures are used to mitigate the heat hazard when working with Cat 3 and above in high temperatures: prehydration, fitness of the worker, shade, rest breaks, a safety observer, awareness of any relevant illness or medications, and continued hydration. This is not an “either/or” situation – you can protect workers from both hazards.
– Scott Margolin, Vice President of Technical, Tyndale Co.
Maintaining thermoregulation in extreme temperatures is increasingly important for workplace safety. The challenge is providing PPE that balances comfort, productivity and cognitive function without compromising safety. PPE alone is not sufficient – safe work practices are equally critical. Staff must be trained to recognize early signs of heat stress, such as dizziness, cramps or impaired function, and cold stress, including numbness, shivering and reduced cognition, which can lead to hypothermia. Preventive measures such as scheduled rest breaks, adequate hydration, and access to shaded or heated shelters support PPE in helping maintain a stable core temperature. For cold environments, ANSI/International Safety Equipment Association 201 classifies protective clothing by thermal insulation to prevent cold-related injuries. The European standard, EN 342, goes further, assessing garments for insulation, wind resistance and moisture protection, as well as providing guidance on safe working times at specific low temperatures depending on wearer activity. In hot environments, fabrics that promote heat and moisture transfer or provide a cool-touch effect enhance wearer comfort. The Qmax test (ASTM D7984) is a globally recognized method for measuring how quickly a fabric draws heat from the skin, with higher values indicating a stronger cooling sensation. Currently, no ANSI equivalent exists. Effective protection in extreme temperatures relies on selecting appropriate clothing, adopting safe work practices, and following protocols to minimize heat- and cold-related risks.
– Kerry Jones, Senior Product Designer, Portwest
When it comes to extreme temperatures, the biggest challenge is finding the right balance between protection and performance. In hot environments, heat stress is a major concern. Workers need breathable PPE that allows body heat to escape, while also supporting sweat evaporation to keep them cool. If the gear traps too much heat, it increases fatigue and the risk of heat-related illness such as heat exhaustion or heatstroke. In cold environments, the opposite problem arises – keeping warmth in. Workers need insulated PPE that can resist compression to maintain loft and warmth. Staying dry is also a concern in cold conditions. Wet hands lose warmth five times faster than dry hands, so workers need PPE that can resist moisture and dry quickly. Layered onto both hot and cold conditions is the need for mechanical protection from other hazards. From cuts, abrasion, impact and more, the real challenge is achieving temperature resistance along with mechanical protection required for the job – all without compromising dexterity, because workers still need to move, grip and perform their tasks efficiently and safely. Ultimately, it’s about providing PPE that balances thermal protection, moisture management and safety features, while ensuring workers can do their jobs effectively.
– Superior Glove, leading safety glove manufacturer
Time is of the essence! Plan ahead so your workers are prepared and outfitted to provide the immediate cooling that’s crucial to prevent long-term complications from heatstroke. If a worker can be cooled to approximately 102° F and serviced by medical professionals within 30 minutes of initial collapse, their chances of survival without health complications are significantly improved. However, if treatment doesn’t occur until 30 minutes after a worker shows symptoms of heatstroke, their chances of developing long-term complications increase. Permanent complications and death become more and more likely if cooling is delayed well beyond 30 minutes. This makes administering first aid incredibly important to prevent serious and deadly health complications.
– John Heniff, Safety Writer, Magid
One of the biggest challenges I see is balancing protection from short duration thermal hazards such as arc flash and flash fire with the real risk of heat stress. A common misconception is that FR/AR clothing itself makes heat stress worse. In fact, research from OSHA, NIOSH and the American Conference of Governmental Industrial Hygienists shows that standard work clothing, including FR/AR shirts and pants, carries the same clothing adjustment factor as non-FR fabrics: zero. In other words, FR/AR garments don’t trap heat or moisture any more than comparable non-FR garments of the same weight. The real challenge is perception and compliance. Workers need to trust that what they’re wearing protects them from arc flash and flash fire without adding unnecessary burden in hot environments. That’s why today’s FR/AR garment development places a lot of value on lighter fabrics, better moisture management and improved breathability. At the end of the day, the fundamentals of heat illness prevention don’t change: hydration, rest and shade. FR/AR clothing’s job is to protect against short-duration thermal exposure. Managing fluids (hydration), recovery (rest) and solar load (shade) is what keeps workers safe in extreme temperatures.
– Derek Sang, Senior Technical Training Manager, Bulwark Protection and Workrite Fire Service
One of the biggest challenges safety professionals face during extreme heat is that workers often feel their PPE makes the problem worse. Protective gear can seem heavy, bulky or not breathable, leading to complaints and even noncompliance. Yet, PPE is designed to protect workers in all environments – removing it to “cool off” can expose them to serious hazards. The good news is today’s PPE manufacturers have made tremendous innovations to help address heat stress. From vented helmets and cooling inserts to high-visibility vests with integrated cooling packs; lightweight, moisture-wicking apparel; and even disposable respirators with exhalation valves that reduce heat inside the device, there are solutions designed specifically to improve comfort and keep body temperature in check. Likewise, PPE has evolved to help workers stay safe and productive in extreme cold, with insulated yet flexible garments, advanced layering systems, and heated gear designed to maintain dexterity and reduce cold stress. To take advantage of these innovations, safety pros should educate themselves on the wide range of options available and work closely with their suppliers to match the right gear to the job and environment. Continued collaboration between safety pros and manufacturers will help to solve this complex workplace safety issue and drive the next generation of heat- and cold-mitigating technologies. Investing in safety is investing in our most valuable resource – our workers.
– Cam Mackey, President and CEO, International Safety Equipment Association
