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-time, 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 due to the reasons mentioned 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 coverall, heavy safety shoes, helmets, gloves, chemical coverall, 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 conducting a TBT (Toolbox Talk) to ensure daily on-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 onsite before the start of work must be delivered without any language barrier, clear and loud. Taking signatures on the TBT attendance sheet ensures that every worker understands today’s TBT. This is a really effective control which can help to reduce the risk of heat stress 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 or normal temperature due to heavy equipment. Oil and gas industries have internal procedures to manage the heat stress; they don’t rely on the trending weather apps. They measure heat index through specialized devices. Based on these readings, a flag system is implemented on site. This flag system declares the is alert for the different activities to follow the rest cycle accordingly.
Example: Every worker must be first acclimatized if comes from a new location or from vacation in the summer. The acclimatization procedure is 2 to 4 hours of light work in 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 works and 10 min break), water after every 15 minutes.
- 🟠 Orange – Temp 35 to 42 – High Risk – 30:20 Work Cycle – Only work in 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 the basic welfare near to 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 safety department is actively monitoring worker breaks and maintaining a log sheet of 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. 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
Structured approach and proper task planning reduce physical strains and keep workers safe. Continuous work tasks are scheduled with work rest cycles using the heat index and flag system. This work is also adjusted by the early morning or late evening, or on the night shift. For example, direct sunlight excavation or pipeline project tasks are only performed in the early morning or on the night shift.
Heat stress safety is very critical, and the heat index log sheet and ensuring compliance 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 accident risk.
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 oil and gas industry in the Gulf, 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 heat stress risk on workers, making the environment safe for them. Oil and gas companies apply engineering controls and site-level controls and spend their 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 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.