Personal protective equipment (PPE) safeguards workers from hazards, yet in high-heat environments, compliance can waver. Discomfort, dehydration, and fatigue often lead to partial use or removal of PPE, exposing workers to heat stress, burns, or severe injury. According to the U.S. Bureau of Labor Statistics, heat exposure continues to cause thousands of workplace illnesses annually, particularly in construction, transportation, and manufacturing sectors (U.S. Bureau of Labor Statistics, 2024).

OSHA’s Heat Illness Prevention campaign urges employers to integrate heat mitigation into PPE programs, emphasizing breathable materials, reflective fabrics, and cooling accessories to improve comfort and compliance (Occupational Safety and Health Administration, 2023). OSHA also stresses frequent rest, hydration, and the use of shaded or air-conditioned recovery areas during extreme heat events (OSHA, 2023).

The National Institute for Occupational Safety and Health (NIOSH) reinforces that heat stress programs must include acclimatization and environmental monitoring. Their Criteria for a Recommended Standard: Occupational Exposure to Heat and Hot Environments outlines engineering and administrative controls such as ventilation, modified schedules, and physiological monitoring to prevent overexposure (National Institute for Occupational Safety and Health NIOSH, 2016).

CDC/NIOSH guidance also supports the use of wearable cooling technologies and smart PPE that monitor body temperature or heart rate, offering real-time protection in high-heat conditions. By coupling technology with training, employers can promote both compliance and comfort (National Institute for Occupational Safety and Health, 2016).

Leadership and culture complete the equation. Supervisors who model correct PPE use and address discomfort through practical solutions such as rotating tasks or providing cooling gear create accountability and trust. EHS professionals can also strengthen compliance by recognizing workers who consistently follow PPE standards, reframing safety as collaboration rather than correction.

At Key Safety LLC, we help organizations confront PPE challenges in heat-intensive settings. Our Document Development for Start-up Projects designs PPE programs tailored to thermal risk. Through Service on Demand, we assess site-specific heat exposures and recommend compliant engineering and administrative controls. Our Regular Consultation Service builds lasting safety cultures that combine comfort, protection, and performance.

When heat rises, PPE non-compliance cannot be tolerated but it can be solved. Smart design, adaptive leadership, and data-informed prevention transform discomfort into protection and compliance into habit.

References

National Institute for Occupational Safety and Health. (2016). Criteria for a recommended standard: Occupational exposure to heat and hot environments (NIOSH Publication No. 2016-106). Centers for Disease Control and Prevention. https://doi.org/10.26616/NIOSHPUB2016106

National Institute for Occupational Safety and Health. (2016, February). Criteria for a recommended standard: Occupational exposure to heat and hot environments (NIOSH Publication No. 2016-106). U.S. Department of Health and Human Services. https://www.cdc.gov/niosh/docs/2016-106/default.html

Occupational Safety and Health Administration. (2023, July 25). Heat illness prevention campaign. U.S. Department of Labor. https://www.osha.gov/heat

Occupational Safety and Health Administration. (2023, July 25). Protecting workers from heat exposure. U.S. Department of Labor. https://www.osha.gov/heat-exposure

U.S. Bureau of Labor Statistics. (2024, March 22). Employer-reported workplace injuries and illnesses, 2023 summary. U.S. Department of Labor. https://www.bls.gov/news.release/osh.toc.htm