In April, the Occupational Safety and Health Administration (OSHA) updated its National Emphasis Program on heat-related hazards. The revised program directs inspections and outreach for 55 high-risk industries in both indoor and outdoor work settings, including “warehousing and storage” under NAICS code 4931.
Why does this matter for facilities managers? Because workers in warehouses, manufacturing plants, distribution centers, and other indoor facilities are exposed to dangerous heat, sometimes even more than those working under the sun.
Offering more hydration alone is not an effective heat safety plan.
Workers performing physical tasks in hot conditions lose fluid through sweat. They also lose electrolytes, including sodium, that help the body maintain fluid balance and function properly. How much they lose depends on the temperature, humidity, workload, protective equipment and clothing, and length of exposure.
Hydration Is a Safety Issue
Dehydration affects more than comfort.
As fluid loss increases, workers may become rundown faster, have difficulty concentrating, and react more slowly, all of which can lead to an injury or fatality. On a job involving vehicles, ladders, machinery, power tools, or electrical systems, slow reaction times and loss of balance from dehydration can increase the risk of an incident.
Heat-related illness can also begin with symptoms that are easy to dismiss. Headache, muscle cramps, unusual fatigue, dizziness, and nausea can all be warning signs that a worker needs attention.
Employees and supervisors should know the early signs of heat illness and know when to stop work. A worker who suddenly slows down, becomes confused, appears unsteady, or shows other signs of heat illness requires immediate assistance.
Hydration is one part of prevention, along with rest, shade, and cooling solutions; workload adjustments; and time to become accustomed to warmer conditions.
Hydration Is the Foundation
Whatever beverage your employees drink should be cool and near to where employees are working. A hydration station on the opposite side of a large property doesn’t help for someone working on a roof, in a mechanical space, or in a remote area of the site.
Workers should be encouraged to drink regularly and not wait until they are extremely thirsty. Flavored, low-sugar beverages are one method employers use to make sure employees are hydrating regularly throughout the day. Drinking smaller amounts throughout the shift is smarter and more effective than trying to catch up after several hours of hard work. OSHA, the National Institute for Occupational Safety and Health (NIOSH), and ANSI/ASSP 10.50 – Standard for Heat Stress Management in Construction and Demolition Operations recommend one quart per hour.
Workers should be encouraged to begin their shifts well-hydrated. A team member who arrives dehydrated may have difficulty catching up once physical work begins.
Facilities should plan for workers who move between buildings, travel across large properties, or cannot easily leave their posts. Contractors, temporary employees, security personnel, equipment operators, and outdoor crews should all be included in your heat stress and hydration plan.
Management must prioritize hydration and make it easily available.
Know When Electrolytes May Help
For a normal workday, cool water or electrolyte replenishment beverages are often enough to replace what workers lose through sweat. But when the day involves several hours of sweating, heavy physical activity, protective clothing, or extreme heat, water isn’t enough on its own. That’s when electrolyte beverages are essential, according to NIOSH.
Electrolytes help the body maintain its fluid balance and keep muscles and nerves working properly. Facilities managers shouldn’t wait until workers experience cramps, unusual fatigue, or dizziness to make these solutions available. Stock them near work and recovery areas, and help supervisors and workers understand when they may be useful, such as after prolonged, heavy work.
Not every product is a good choice. Look for drinks with balanced electrolytes (electrolytes that are 8% of sodium by volume, as defined by NIOSH), and steer clear of energy drinks or options loaded with caffeine or sugar. Also consider workers with medical conditions or those taking certain medications, who may need guidance from a healthcare professional. There are a number of electrolyte replenishment beverages that have lower sodium and low sugar available for those who are hypertensive, diabetic, or pre-diabetic.
Most importantly, electrolytes are only one part of a good heat safety program. They don’t replace rest breaks, shade or air conditioning, acclimatization, or steps to reduce workers’ heat exposure and workload.
Match the Plan to the Conditions
Heat exposure can vary widely within the same facility and across the same shift. Use of a portable wet bulb globe temperature (WBGT) device can tell you the heat impact a worker is experiencing. These devices can be used both indoors and outdoors. A WBGT device can provide information that can help you know when workers should take a break.
Indoor work isn’t automatically low risk either. Warehouses, boiler rooms, kitchens, and laundry areas can pose a heat illness risk. According to OSHA, heat-related inspections accounted for 6% of all federal occupational safety and health inspections over the past five years, up from just 0.5% in the five years before the original program launched.
A task that’s manageable at 8 a.m. may become much more demanding by mid-afternoon. Supervisors should have clear authority to add breaks, rotate employees, or move work to a cooler time when conditions worsen. Hydration stations should be checked throughout the shift, not just set up at the start of the day. Water runs out. Coolers get warm. Cups disappear.
The plan needs to work under actual job conditions, not only on paper.
Review the Plan Before the Next Heat Event
Heat planning should begin before the heat hits.
Facilities should review their programs before temperatures rise and again after a major heat event. Managers should determine whether cool beverages remained available, whether workers could reach cooling areas, whether supervisors recognized warning signs, and whether schedules or workloads were adjusted when needed.
Those reviews can reveal gaps before they put workers at greater risk. With federal enforcement now targeting indoor facilities directly and a permanent heat standard still without a finalization date, that review can’t wait for the next OSHA visit to happen first.
Dan Glucksman is the senior director of policy at the International Safety Equipment Association (ISEA).