Beat the Heat: Best Practices for Cooling Road-Crew PPE in Triple-Digit Temps
Keep highway and paving crews safe, compliant, and productive when summer temperatures soar past 100°F.As scorching summers push work zone temperatures into triple digits, heat illness is a growing threat for road crews. With OSHA’s new Heat Injury & Illness Prevention rule nearing enforcement, ensuring your team stays cool, safe, and compliant is critical. This guide from Traffic Safety Store breaks down proven cooling strategies for personal protective equipment (PPE) and work practices to protect your crew and keep projects on track.
1. The Rising Danger of Heat in Work Zones
In 2023, 55 U.S. workers died from heat exposure, with construction accounting for a third of these fatalities. Road crews face unique risks due to prolonged sun exposure, reflective asphalt, and heavy PPE. OSHA’s first nationwide heat rule, finalized with public hearings on July 2, 2025, signals stricter compliance requirements and potential citations for unprepared employers. Acting now isn’t just about safety—it’s about avoiding costly penalties.
2. Why Standard PPE Intensifies Heat Stress
PPE like high-visibility vests, hard hats, gloves, and steel-toe boots is essential for safety but traps heat, increasing core body temperatures. Heat stress arises from:
Metabolic heat from physical labor
Ambient heat from sun and hot surfaces
Clothing resistance that blocks cooling
When the heat index exceeds 100°F, standard PPE can push core temperatures above safe levels within an hour. Cooling-focused PPE is a game-changer for crew comfort and safety.
3. Worksite Strategies to Support Cooling PPE
Cooling PPE works best when paired with administrative and engineering controls. Here’s how to create a heat-safe work zone:
Shade & Airflow: Provide tents or awnings for every 10 workers and use battery-powered misting fans when the Wet Bulb Globe Temperature (WBGT) exceeds 88°F.
Hydration Protocol: Encourage 32 oz/hour, alternating water with electrolyte drinks to prevent dehydration.
Work-Rest Scheduling: For “very high” heat, implement 45 minutes of work followed by 15 minutes of rest per hour in full sun.
Acclimatization: Gradually increase new workers’ exposure from 20% to full workload over 7–14 days.
Night or Dawn Shifts: Schedule paving from 8 p.m. to 6 a.m. when possible, using reflective traffic drums and channelizers, available at Traffic Safety Store.
4. Procurement & Maintenance Checklist
Investing in cooling PPE is cost-effective compared to heat-related downtime or OSHA fines. Use this checklist to get started:
Select ANSI 107 Class 2/3 garments with proven cooling technology.
Choose phase-change packs rated for 200+ freeze cycles.
Budget for two pack sets per vest to ensure all-shift cooling.
Train crews to wash cooling fabrics separately, avoiding fabric softeners that clog wicking pores.
Inspect hard hat and safety helmet vents weekly and replace sweatbands every 30 days during peak season.
In July 2024, Caltrans equipped crews with cooling PPE for a 107°F asphalt project near Palm Springs. The result? Zero heat-related incidents over 22 night shifts, compared to four cases the previous summer without cooling PPE. This success highlights the power of combining smart PPE with strategic scheduling.
6. Why Cooling PPE Is a Win-Win
Cooling-optimized PPE, paired with shade, hydration, and smart scheduling, reduces heat stress, boosts productivity, and ensures compliance with OSHA’s looming heat rule. For a fraction of the cost of a single heat-related incident, you can protect your crew, avoid delays, and keep projects on schedule.
Ready to equip your team? Explore cooling PPE and worksite safety solutions at Traffic Safety Store to beat the heat and stay compliant.
