When temperatures drop, so does the body’s ability to maintain its core heat and that’s when cold stress becomes a serious concern for outdoor and industrial workers. Whether you’re in utilities, construction, foundry work, or transportation, understanding the risks of cold exposure is critical to keeping your crew safe and productive.
What Is Cold Stress?
Cold stress occurs when the body can’t maintain its normal temperature due to exposure to cold air, wind, or wet conditions. As the body loses heat faster than it can produce it, the internal temperature drops leading to serious health risks such as:
- Hypothermia: When body temperature falls below 95°F, leading to confusion, fatigue, and potentially death if untreated.
- Frostbite: Freezing of skin and tissue, often affecting fingers, toes, ears, and nose.
- Trench Foot: Caused by prolonged exposure to wet, cold conditions, leading to numbness, swelling, and tissue damage.
Even moderately cold temperatures can become dangerous when combined with wind or moisture a major factor in winter job sites, confined spaces, and utility work in the Great Lakes region.
Recognizing the Signs
Early detection saves lives. Look for these warning signs among your crew:
- Shivering, slurred speech, or disorientation (early hypothermia)
- Pale, hard, or waxy skin (frostbite)
- Tingling or numbness in the feet (trench foot)
- Fatigue, clumsiness, or confusion — all signals that a worker’s body is losing heat faster than it can recover
Supervisors and safety leads should train workers to monitor each other, especially during long shifts or windy, wet days.
Prevention: Layer, Shield, and Stay Dry
The best defense against cold stress is proper PPE and preparation.
1. Layer Up
Use multiple layers to trap body heat:
- Base Layer: Moisture-wicking FR thermals or TECGEN SELECT® FR shirts that keep sweat away from the skin.
- Middle Layer: Insulating fleece or wool for warmth and comfort.
- Outer Layer: Windproof and waterproof gear like the DRIFIRE FR DuoStorm Jacket Class 3 and DuoStorm Bib that block wind and repel water.
2. Protect Extremities
Hands, feet, and head lose heat quickly. Choose:
- FR-rated gloves designed for dexterity and warmth
- FR balaclavas for head and face coverage under hard hats
3. Take Breaks and Stay Dry
Encourage frequent warm-up breaks in heated shelters and provide warm fluids (avoid caffeine and alcohol). Replace wet clothing immediately and rotate workers when exposure is prolonged.
Employer Responsibilities
According to OSHA’s Cold Stress Guide, employers must take proactive measures to protect workers exposed to cold environments. This includes:
- Conducting regular training on cold stress recognition and prevention
- Adjusting work schedules during extreme weather
- Providing heated shelters and emergency supplies
- Supplying appropriate FR cold-weather PPE
Employers should also follow NFPA 70E and OSHA 1910.269 standards to ensure compliance for workers exposed to both cold and electrical hazards.
Shop Novarlo’s Cold-Weather PPE Picks
At Novarlo, we carry FR cold-weather gear engineered to handle harsh environments while meeting all major industry standards. Gear up with trusted brands like DRIFIRE®, Ariat FR®, Blaklader, and Enespro®.
Top Cold-Weather Picks:
- PW3 Hi-Vis 3-in-1 Jacket
- DRIFIRE® DuoStorm Bib
- Ariat - Mens FR Basic Insulated Jacket
- FR Balaclavas & Face Protection
- Thermal FR Gloves
Equip your crew before winter hits because safety doesn’t stop when temperatures drop.
Stay Warm. Stay Compliant. Stay Working.
Cold stress isn’t just discomfort it’s a preventable hazard that can lead to serious injury or death. With the right training, FR cold-weather gear, and preparation, your team can stay warm, compliant, and productive all winter long.