Male worker shoveling snow on a utility site while wearing HiVis.

How to Safely Manage & Prevent Cold Stress

If you work long hours in cold environments, read on to learn about cold stress, its risk factors and how to prevent it while maintaining a safe workplace for employees.

Man walking outdoors in a snowy, cold environment

Understanding Cold Stress and its Risk Factors

As stated in RefrigiWear’s contribution to the Public Safety Journal’s article, Understanding & Preventing Cold Stress, cold stress occurs when the body loses heat faster than it can produce it, leading to critical conditions such as frostbite, hypothermia and trench foot. In cold environments, the body prioritizes core temperature by diverting blood from extremities, increasing the risk of cold stress and cold-related injuries. Workers in outdoor or temperature-controlled indoor settings, like construction, agriculture, refrigerated warehouses, and cold storage, are at great risk. Factors such as windy or wet conditions and preexisting health conditions like diabetes or hypothyroidism further elevate the risk.

It doesn’t need to be bitterly cold for cold stress symptoms to set in. Even at 50°F, you can notice the following symptoms:

  • Shivering
  • Fatigue or drowsiness
  • Tingling sensation followed by numbness
  • Disorientation or confusion
  • Slurred speech
  • Changes in skin color, such as turning from red to purple to white
  • Changes in skin texture, such as a waxy appearance

    • If left untreated, these can escalate to severe conditions, like:

  • Hypothermia: A life-threatening drop in body temperature (<95°F), impairing vital organs and potentially causing death.
  • Frostbite: Freezing of skin and tissues, commonly affecting extremities like fingers, toes, and ears, which may result in permanent damage or amputation.
  • Trench Foot: A nonfreezing injury caused by prolonged exposure to damp, cool conditions, leading to infections or severe tissue damage.

    • Best Gear for Preventing Cold Stress

    Man sitting indoors in insulated base layers

    Lightweight Base Layer Top: Take the warmth of your jacket a step further by starting your work uniform off with a moisture-wicking base layer that could boost your warmth 4°F to 8°F degrees more.

    SHOP LIGHTWEIGHT BASE LAYER TOP

    Outdoor worker carrying timber while wearing insulated PPE to prevent heat loss

    Extreme Sweater Jacket: Stay warm and stylish without compromising on durability. The Extreme Sweater Jacket is designed for demanding conditions, offering protection against freezing temperatures down to 10°F. The water-repellent, wind-tight finish shields you from harsh winter elements, while the full-zip, stand-up collar prevents cold drafts. Reflective silver piping and HiVis lime accents provide added safety in low-light conditions. This jacket is perfect for outdoor work, freezer environments or everyday winter wear.

    SHOP EXTREME SWEATER JACKET

    Outdoor worker on a ranch wearing HiVis insulated PPE

    HiVis Waterproof Bomber Jacket: The HiVis Waterproof Bomber Jacket is designed to keep you warm, dry and visible while handling the most demanding jobs in cold and wet conditions. A fleece-lined outer shell and rollout hood provide protection against rain, snow and wind.

    SHOP HIVIS WATERPROOF BOMBER

    Worker in outdoor col environment wearing a hard hat balaclava

    Hard Hat Balaclava: Stay protected from cold temperatures without sacrificing safety on the job. The RefrigiWear Hard Hat Balaclava is specifically designed to fit securely around hard hats, sealing out drafts and keeping you warm in low-temperature environments. With a double-layer acrylic knit construction, it offers superior insulation for your head, face and neck, ensuring maximum comfort in harsh conditions. The extended neck design provides additional draft protection, making it a reliable choice for workers exposed to extreme cold.

    SHOP HARD HAT BALACLAVA

    Insulated gloves for preventing cold stress

    Frostline® Glove: Stay warm and protected in extreme cold with the Frostline® Glove, designed to handle temperatures as low as -25°F. Built for durability, these gloves feature a waterproof outer shell to keep your hands dry and insulation that extends through the cuff for enhanced warmth. Key features include reinforced palms, thumbs and fingers for rugged use, plus Performance-Flex knuckles to ensure ease of movement and a strong grip in any condition. The lightweight yet highly durable design makes these gloves perfect for both indoor and outdoor tasks. Reflective piping adds visibility, while a convenient pull tab with a rubber ID tag makes them easy to handle.

    SHOP FROSTLINE® GLOVE

    Insulated hiker boots for low temperature work in cold environments

    PolarForce® Hiker Boot: Take on extreme winter conditions with the PolarForce® Hiker Boot, designed for unmatched durability, safety and comfort. Engineered for temperatures as low as -30°F, these waterproof boots provide the ultimate defense against harsh environments while keeping your feet dry and fatigue-free. Whether you're managing inventory, repairing fences, or unloading shipments, PolarForce® ensures you stay steady and safe throughout the day.

    SHOP POLARFORCE® HIKER BOOT

    Employer Commitments to Cold Stress Prevention

    Employers have a major responsibility to create a safe work environment for employees exposed to cold conditions, as OSHA does not provide specific standards for cold stress or cold-related hazards. Instead, employers must proactively establish policies, offer training and provide proper equipment to protect workers.

    Employers should implement policies that allow flexibility in working through extremely cold conditions, as recommended by NIOSH. This includes assigning additional workers for demanding tasks and scheduling relief workers to reduce lengthy exposure to cold. Policies should also include adequate warming breaks in designated heated areas, with adjustments made based on temperature, wind speed and work intensity. For example, shorter work periods and more frequent warming breaks are essential as conditions worsen.

    Annual training is crucial for preparing employees to work in cold environments. Training should cover the risks of cold stress, recognition of early symptoms and the dangers of severe conditions like hypothermia, frostbite and trench foot. Educating employees on emergency response protocols ensures they are equipped to address cold-related incidents quickly and effectively.

    Outfitting with Insulated PPE

    Employers must ensure workers are properly outfitted for cold conditions to prevent heat loss. Whether directly provided, through stipends or through clear guidance on requirements, insulated PPE is essential. Employers should emphasize the use of layered clothing, insulated gloves, boots and other gear suited to the work environment, setting clear expectations for safety standards because this gear is an employee's first line of defense against the cold.

    When you start constructing your work uniform for the day, consider synthetic, moisture-wicking base layers, add an insulated mid-layer and top it off with waterproof outerwear. Don’t forget gear that covers your entire body, like waterproof boots with warm liners, insulated gloves with liners and neck and face protection like a balaclava. Also, pick insulated PPE that fits well but isn’t too tight—tight clothes can cut off circulation and make it harder to stay warm.

    By adopting these measures, employers can help their workers mitigate the risks associated with cold stress, ensuring worker safety and productivity in challenging environments.

    Cold weather is tough, but with the right gear and a little common sense, you’ll power through and get the job done. Stay sharp, stay warm and don’t cut corners on your safety.