Managing Heat Stress in Industrial Work Environments

As temperatures begin to rise in the warmer months, many businesses operating in large industrial buildings face a significant challenge: keeping their workforce safe and productive in the heat. While heat stress is often associated with outdoor work, indoor environments such as manufacturing facilities, warehouses, and logistics hubs can quickly become hot, uncomfortable, and even dangerous if not properly managed.

Under UK and Irish health and safety regulations, employers have a clear responsibility to ensure that working conditions do not put staff at risk. The Health and Safety Executive (HSE) in the UK, for example, sets out clear guidelines requiring employers to manage the risks associated with high temperatures and provide a safe working environment. Similarly, the Health and Safety Authority (HSA) in Ireland expects proactive measures to be taken.

Understanding how to prevent heat stress and manage indoor temperatures effectively is not only about compliance, it is about safeguarding the wellbeing of your employees and maintaining operational efficiency.

Why Heat Stress Matters

Heat stress occurs when the body is unable to regulate its internal temperature. In an industrial setting, this can happen even when outdoor temperatures are moderate if the internal environment lacks adequate ventilation or insulation. Activities involving physical exertion, machinery that generates heat, and high levels of solar gain through poorly insulated structures all contribute to the risk.

Common symptoms of heat stress include fatigue, dizziness, headaches, nausea, and, in more severe cases, heat exhaustion or heat stroke – a potentially life-threatening condition. Even before reaching this point, high temperatures can lead to reduced concentration, slower reaction times, and increased risk of accidents, all of which impact both safety and productivity.

Legal Considerations

Under the UK’s Workplace (Health, Safety and Welfare) Regulations 1992, employers are required to provide a “reasonable” temperature in indoor workplaces. While no specific maximum temperature is legally defined, the law places responsibility on employers to assess risk and act accordingly. The Management of Health and Safety at Work Regulations 1999 further require employers to conduct suitable risk assessments and implement measures to mitigate hazards such as heat.

Ireland’s General Application Regulations also require that temperature in workrooms must be “appropriate having regard to the working methods being used and the physical demands placed on the employees.” Failure to manage heat stress effectively could expose businesses to liability in the event of illness or injury.

What Contributes to Heat Build-Up in Industrial Buildings?

Several factors can cause temperatures in industrial settings to soar. Metal structures and uninsulated walls or roofs are particularly prone to absorbing and radiating heat. Large, open-plan buildings with high ceilings can become heat traps, particularly if they rely on poor natural ventilation. Machinery and equipment can add further heat to the environment.

Warehouse and logistics operations often have a high throughput of goods, meaning doors are opened frequently, bringing in warm air. Conversely, sealed buildings without adequate airflow can retain heat for long periods. The materials stored inside also matter — certain products may release heat or affect humidity, further compounding the issue.

Proactive Steps to Manage Heat Stress

Managing heat stress requires a combination of structural, procedural, and behavioural interventions.

One of the most effective long-term solutions is to improve the thermal performance of the building itself. Upgrading to insulated structures can dramatically reduce heat build-up. For example, Lauralu’s insulated temporary and semi-permanent buildings use advanced cladding and roofing systems that limit solar gain and improve temperature stability throughout the year. This not only helps manage heat during summer but also improves energy efficiency and comfort in winter.

Ventilation is equally important. Mechanical ventilation, industrial fans, and well-designed openings can promote airflow and help remove hot air from the workspace. When planning a new building or considering a temporary extension, it is worth assessing the ventilation strategy early in the process.

Operational practices also play a key role. Rotating tasks to minimise physical exertion in hot conditions, encouraging regular hydration breaks, and adjusting shift patterns to cooler parts of the day are all practical measures that can make a difference. Providing easy access to cool drinking water and shaded rest areas is essential.

Personal protective equipment (PPE) should also be reviewed. While some roles require PPE regardless of temperature, ensuring it is appropriate for warm conditions and made from breathable materials can reduce the risk of overheating.

Why Businesses Should Act Now

There are strong business reasons to invest in heat management now, rather than wait for a crisis. A comfortable working environment helps retain staff, particularly in industries already facing labour shortages. It also supports productivity. Employees working in a well-regulated climate are more focused, safer, and less likely to take heat-related sick leave.

Future climate trends are another consideration. The Met Office predicts that UK and Irish summers will continue to grow hotter and more frequent heatwaves are expected. Businesses that rely on large indoor spaces cannot afford to take a reactive approach. Building resilience now is a strategic investment.