Introduction
In the Gulf countries such as Qatar, Saudi Arabia, and the UAE, summer temperatures can easily exceed 45℃. Working in the oil and gas industry in these countries is not only technically demanding but also physically challenging due to extreme weather conditions, which significantly increase the risk of heat stress. In this environment, one of the biggest concerns is heat stress safety; if it’s not controlled properly, heat stress can lead to fatigue, dehydration, heat exhaustion, and even fatality.
In this article, we will break down seven essential procedural steps commonly used in the oil and gas industry and widely implemented across companies in the Gulf region. These steps help effectively manage heat-stress risks for workers, based on real-world, practical examples.
What is Heat Stress?
Heat stress occurs when the body is unable to regulate or cool itself effectively due to high temperatures, humidity, and intense physical activity or heavy workloads. In oil and gas operations, the risk of heat stress increases for the reasons outlined below.
- Outdoor or direct sunlight work exposure – e.g., ongoing civil work activities in the plant area.
- Limited airflow in the process area – e.g., confined space, mechanical job on equipment or pipe rack.
- Personal Protective equipment (PPE) – e.g., fire-retardant coveralls, heavy safety shoes, helmets, gloves, chemical coveralls, and special PPEs
These factors can increase the risk of heat stress, which is why companies in the Gulf region implement strict heat stress mitigation programs to protect workers’ health. The essential steps that every worker must follow to ensure heat stress safety are listed below:
1. Tool Box Talk (TBT)
The first and most important step is to conduct a TBT (Toolbox Talk) to ensure daily on-the-ground awareness at the start of the shift and before beginning any activity. The Safety department ensures that TBT must include the heat stress safety point in their TBT, such as:
- Current weather condition
- Understanding the heat index level announcement and responding accordingly
- Symptoms of heat stress
- Any previous shift incident of heat stress
- Preventive actions
This TBT, in the morning and on-site before the start of work, must be delivered clearly and loudly, without any language barrier. Taking signatures on the TBT attendance sheet ensures that every worker understands today’s TBT. This is a really effective control that can help reduce the risk of heat stress by up to 50%.
Note: Word of mouth is more effective than documentation and checklists.
2. Measuring heat index & flag management system
In the process area, the temperature will be higher than the non-process (normal) temperature due to heavy equipment. The oil and gas industry has internal procedures to manage heat stress; it doesn’t rely on trending weather apps. They measure heat index through specialized devices. Based on these readings, a flag system is implemented on site. This flag system signals alerts for different activities to follow the rest cycle accordingly.
Example: Every worker must first be acclimatized if they come from a new location or return from summer vacation. The acclimatization procedure consists of 2 to 4 hours of light work during the 12-hour shift for 1 week. After 1 week, workers are allowed to work 12-hour shifts, but following the heat index indication, which includes:
- 🟢 Green –Temp Below 28℃ – Normal condition – Work with desired breaks.
- 🟡 Yellow – Temp between 29 to 34 – Caution required – 40:10 work cycle (40 min work and 10 min break), water after every 15 minutes.
- 🟠 Orange – Temp 35 to 42 – High Risk – 30:20 Work Cycle – Only work in a shaded area
- 🔴 Red – Temp 43 to 50 – Extreme risk – 20:20 work cycle – Only light activities, no heavy work.
Note: This is a general system; every company has its own work cycle system and work restrictions. They provide their heat index chart and training to every worker to ensure heat stress mitigations
3. Cool Rest Shelter
Welfare is essential to lower the risk of heat stress. Continuous work or only breaks without cooling is very dangerous. That’s why companies provide basic welfare near every work site in summer from 01 April to 31 Oct, which includes
- Cooling Rest shelter with a cooling fan or AC
- Drinking water stations with cool water
- Proper and comfortable seating arrangements for manpower.
Workers are encouraged to take breaks; the safety department actively monitors breaks and maintains a log sheet for each worker’s work and rest cycle.
4. Heat stress risk screening
New workers are more vulnerable because their bodies are not adapted to extreme heat. Proper screening helps prevent incidents before they happen. Before issuing the Permit to Work, risk screening is performed for the activity, and a heat stress checklist and mitigation document are attached to the permit. The permit issuer and HSE department ensure:
- Identifying high-risk jobs (e.g., welding, confined space work)
- Checking worker fitness and medical conditions
- Monitoring new or unacclimatized workers
5. Task planning and work rest cycle
A structured approach and proper task planning reduce physical strain and keep workers safe. Continuous work tasks are scheduled using work-rest cycles based on the heat index and flag system. This work is also adjusted to early mornings, late evenings, or the night shift. For example, direct-sunlight excavation or pipeline project tasks are performed only in the early morning or on the night shift.
Heat stress safety is critical, and the heat index log sheet and compliance monitoring are two of the most effective controls.
6. Hydration, Nutrition & Proper Sleep
Dehydration is one of the biggest hidden risks. Even a small drop in hydration can affect concentration and increase the risk of accidents.
The safety department ensures that the workers are trained and comply with:
- Drink water regularly (not just when thirsty)
- Carry personal water bottles at all times
- Avoid energy drinks and excessive caffeine
- Eat light and healthy meals
- Get proper sleep before shifts
Note: In the Gulf oil and gas industry, there is a strict rule for personal water bottles: “no bottle, no work.” There is a safety team whose duty is to ensure the workers keep a water bottle before entering the site.
7. Site Mitigation Measures
Mitigation steps reduce the overall risk of heat stress for workers, making the environment safer for them. Oil and gas companies implement engineering and site-level controls and allocate financial resources to reduce heat exposure. These controls include:
- Installing temporary shades over the work area
- Providing mechanically operated ventilation
- Hiring extra manpower for rotation and work-rest cycle
- Extra training and summer safety program
- Increasing the number of safety professionals to enforce compliance
Final Thoughts
In the oil and gas industry across Gulf countries, heat stress is a serious hazard. However, its effects can be effectively controlled with the right systems and procedures in place. At the end of the day, safety is a shared responsibility. Companies establish procedures and provide the necessary facilities, while workers must follow safety guidelines and procedures set by the safety department and take responsibility for their own health.