Build a heat stress program in 8 steps

What is a heat stress program, and why write one down?

A heat stress program is a written plan that finds heat hazards, sets controls and says what to do when someone gets sick. OSHA says “Employers should create a written plan to prevent heat-related illness.” A written plan turns good intent into daily habits that a new foreman can follow.

OSHA also says “Heat-related illness is preventable, especially with management commitment to providing the most effective controls.” No final federal OSHA heat standard exists as of November 2026, so this guide follows OSHA and NIOSH guidance. It is not legal advice. See our OSHA heat illness prevention guide for the rule status.

Use the eight steps below. Together they make a heat illness prevention plan you can adapt to a site, a shift or a fleet.

Step 1: Who should run the heat plan each day?

Name one trained person per site. OSHA says an individual at the worksite “should be responsible for monitoring conditions and implementing the employer’s heat plan throughout the workday.” That can be a foreman, jobsite supervisor, plant manager or safety director.

OSHA says proper training includes knowing how to identify and control heat hazards, recognize early symptoms, give first aid and activate emergency medical services quickly. Give the lead authority to slow work and call a break. A lead who needs permission to stop work will not stop it in time.

Step 2: How do you measure heat at the site?

Use a WBGT meter near the work. OSHA says “Workplace environmental heat should be measured on-site using WBGT meters.” The heat index is a less desirable substitute. Our WBGT vs heat index guide shows OSHA’s limits by workload.

OSHA says employers must assess both the environment and the work. Environmental heat comes from the weather. Metabolic heat comes from the work. Heavy and very heavy tasks carry the highest risk. Record the reading, the time and the task, so you can show what you knew and when.

Step 3: What triggers extra controls on a hot day?

Set triggers in writing before summer starts. NIOSH says to use a heat alert program whenever the weather service forecasts a heat wave. OSHA’s planning page asks employers how they will respond when the National Weather Service issues a heat advisory or heat warning.

Pick clear triggers, such as an NWS advisory, a WBGT limit or the first hot week of spring. Then list what changes: more breaks, earlier start times, more water stations, more buddy checks and fewer solo tasks. The OSHA Heat NEP adds random heat inspections in high-risk industries on NWS advisory or warning days, so these days matter twice.

Step 4: How do water, rest and shade work in the program?

Apply Water. Rest. Shade. every shift. OSHA says it “encourages water, rest, and shade as prevention as well as treatment for heat-related illness.” See the Water. Rest. Shade. entry for the idea in short form.

• Water. NIOSH says to provide adequate amounts of cool, potable water near the work area and encourage workers to drink often. OSHA says workers “should not rely on feeling thirsty.”
• Rest. OSHA says rest breaks should get longer and more frequent as heat stress rises, and that skipping breaks in hot conditions is not safe.
• Shade. OSHA says give workers “a cool location where they can take their breaks and recover from the heat.” Outdoors that can be shade, an air-conditioned vehicle, a tent, or an area with fans and misting.
• Electrolytes. OSHA says that on jobs longer than two hours, employers “should provide electrolyte-containing beverages such as sports drinks.” NIOSH says fluid intake should not exceed 6 cups per hour.

Step 5: How do you acclimatize new and returning workers?

Ramp up exposure over days. NIOSH says to gradually increase workers’ time in hot conditions over 7 to 14 days. OSHA says almost half of heat-related deaths happen on a worker’s first day on the job or first day back after an extended absence.

Use the 20 percent rule for new workers: 20 percent of normal heat exposure on day one, then add 20 percent per day. Keep the intensity of the work the same; shorten the time. Our heat acclimatization schedule has a full table. Add a buddy system, which NIOSH recommends.

Step 6: What should heat training cover?

Cover signs, causes, first aid and who to tell. NIOSH says to train workers before hot outdoor work begins and to provide a heat stress training program for all workers and supervisors. Supervisors need extra training on acclimatization, emergency response, weather monitoring and fluid intake.

Topics for every worker:

1. Signs and symptoms of heat-related illness, and first aid.
2. Why drinking enough and watching urine color and amount matter.
3. How clothing and PPE add heat.
4. Why acclimatization matters.
5. Report your own symptoms and a coworker’s right away.
6. How to call emergency medical services.

Short toolbox talks keep the habit alive. See the toolbox talk entry. JMAR Solutions also offers onsite toolbox talks as part of its hydration programs.

Step 7: What is the first aid and 911 plan?

Heat stroke is a 911 emergency. NIOSH says: “Call 911 for emergency medical care.” Move the worker to a cool area, remove outer clothing, cool the worker fast, and stay until emergency medical services arrive. OSHA adds: “When in doubt, cool the worker and call 911.”

Write the plan on one card per site:

1. Who calls 911 and who meets the ambulance.
2. Where the shade or cool area is, and where ice or cold water is kept.
3. Who stays with the worker. OSHA says never leave a worker with heat-related illness alone.
4. The exact address and gate for emergency crews.

OSHA’s first aid standards require ready first aid personnel and equipment. Compare the two big illnesses in our heat exhaustion vs heat stroke guide.

Step 8: How do you review and improve the program?

Review after each heat event and each season. OSHA says employers must report work-related deaths within eight hours and inpatient hospitalizations within twenty-four hours. Keep logs of readings, breaks, training dates and near misses.

Ask three questions after each hot week: Did the lead call breaks early enough? Did new workers get the ramp-up? Did every supervisor know the 911 steps? Fix gaps before the next advisory day. OSHA’s On-Site Consultation Program is free and confidential for small and medium-sized businesses and can help with this review.

What should a daily heat checklist include?

Keep one page on the clipboard, and have the heat lead fill it out each shift. OSHA says heat conditions can change rapidly and that adjusting controls is critical to prevent heat illness.

OSHA says weather reports are unlikely to give accurate heat estimates at sites with features such as direct sun, hot equipment or indoor work. Fill the sheet from what you see on site.

Where does hydration fit, and what does JMAR offer?

Hydration is one step in eight, not the whole program. JMAR Solutions supports step 4. Rapid Restoration Drops are a dietary supplement that replaces electrolytes lost in sweat and supports hydration. They are unflavored, with no sugar and no calories. They do not replace water, rest, shade or first aid.

JMAR’s hydration programs work with safety managers to create, educate and coach. For the full prevention frame, read our heat stress prevention pillar.

Next step

Ready to put these eight steps on paper for your crew? Book a 15-minute demo with JMAR Solutions, or ask about bulk and government pricing.