Product Overview

Summary: This Heat Stress Management Safe Operating Procedure provides a clear, practical framework for preventing heat-related illness in Australian workplaces. It sets out how to identify heat risks, implement control measures, and respond effectively to signs of heat stress, helping you protect workers and meet your WHS obligations during hot and humid conditions.

Australian workplaces are increasingly exposed to extreme heat, whether from hot weather, radiant heat from plant and equipment, or enclosed workspaces with poor ventilation. Without a structured approach, workers can quickly move from discomfort to heat exhaustion or heat stroke, with serious medical consequences and legal implications for the business. This Heat Stress Management SOP translates regulatory expectations and best practice guidance into a practical, step-by-step procedure that supervisors and workers can apply on the ground.

The document covers how to assess heat risks, plan work around environmental conditions, implement engineering and administrative controls, and ensure adequate hydration, rest breaks, and acclimatisation. It clarifies when work should be modified, rescheduled, or stopped, and provides clear guidance on recognising early warning signs and responding to heat-related incidents. By adopting this SOP, organisations can reduce incident rates, demonstrate due diligence under WHS legislation, and provide a defensible system of work that stands up to internal audits, regulator scrutiny, and insurance reviews.

Designed specifically for Australian conditions, this SOP supports businesses across construction, mining, agriculture, manufacturing, warehousing, utilities, and outdoor services. It helps standardise decision-making on hot days, reduces disputes between workers and supervisors about when it is safe to work, and embeds a consistent, documented approach to managing heat stress in line with contemporary WHS expectations.

Key Benefits

• Reduce the risk of heat exhaustion, heat stroke, and related medical emergencies through structured controls and monitoring.
• Ensure compliance with Australian WHS legislation and guidance on managing extreme heat and thermal comfort.
• Standardise how supervisors assess heat conditions, schedule work, and implement rest and hydration breaks.
• Demonstrate due diligence to regulators, clients, and insurers with a documented, defensible system for managing heat stress.
• Improve worker comfort, engagement, and productivity during hot weather by setting clear expectations and controls.

Who is this for?

• WHS Managers
• Health and Safety Advisors
• Site Supervisors
• Construction Project Managers
• Operations Managers
• Facilities Managers
• HSE Coordinators
• Manufacturing Supervisors
• Agricultural and Horticultural Managers
• Mining and Resources Supervisors
• Emergency Response Team Leaders
• Labour Hire Providers

Hazards Addressed

• Heat exhaustion and heat stroke from working in high ambient temperatures
• Dehydration due to inadequate fluid intake during hot work
• Exacerbation of pre-existing medical conditions (e.g. cardiovascular issues) due to heat exposure
• Reduced concentration and decision-making leading to errors and incidents
• Thermal burns from contact with hot surfaces, equipment, or materials
• Fatigue and manual handling injuries associated with working in heat-stressed conditions
• Heat cramps and fainting (syncope) during or after physical exertion in hot environments

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Heat Stress, Heat Strain, WBGT, Acclimatisation, etc.)
• 3.0 Roles and Responsibilities (PCBUs, Officers, Supervisors, Workers, First Aiders)
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Heat Hazard Identification and Risk Assessment
• 6.0 Environmental and Workload Assessment (including use of WBGT or local heat indices)
• 7.0 Risk Control Measures – Hierarchy of Controls
• 7.1 Engineering Controls (shade, ventilation, cooling, insulation)
• 7.2 Administrative Controls (work-rest regimes, job rotation, scheduling)
• 7.3 Hydration and Fluid Replacement Requirements
• 7.4 Acclimatisation Procedures for New and Returning Workers
• 8.0 PPE and Clothing Requirements for Hot Conditions
• 9.0 Planning Work in Hot and Humid Weather (including trigger points and stop-work criteria)
• 10.0 Monitoring Workers for Signs of Heat Stress
• 11.0 Health Considerations and Fitness for Work (medications, pre-existing conditions)
• 12.0 Communication, Consultation and Worker Training
• 13.0 Step-by-Step Procedure for Managing Heat Stress on Site
• 14.0 Emergency Response for Heat-Related Illness
• 15.0 Incident Reporting, Investigation and Corrective Actions
• 16.0 Recordkeeping (heat assessments, training, incidents, medical responses)
• 17.0 Review, Audit and Continuous Improvement
• Appendix A – Heat Stress Symptoms and First Aid Guide
• Appendix B – Example Work-Rest and Hydration Schedules
• Appendix C – Sample Heat Stress Risk Assessment Checklist
• Appendix D – Example Daily Heat Management Plan / Pre-Start Template

Legislation & References

• Work Health and Safety Act 2011 (Cth) and harmonised state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory regulations
• Safe Work Australia – Guide for Managing the Risks of Working in Heat
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – How to Manage Work Health and Safety Risks (Code of Practice)
• AS/NZS 45001:2018 Occupational health and safety management systems – Requirements with guidance for use
• ISO 7243: Ergonomics of the thermal environment – Assessment of heat stress using the WBGT index (as guidance where adopted)