What are the legal requirements for managing heat stress in Australia?

Under the WHS Act s19, the PCBU has a primary duty of care to ensure, so far as is reasonably practicable, the health and safety of workers. This includes managing the risk of heat-related illness. WHS Regulations Chapter 3 Part 3.1 requires the PCBU to identify hazards, assess risks and implement controls. Safe Work Australia has published a guide on managing the risks of working in heat, which recommends monitoring environmental conditions, assessing the physical demands of work, providing water, shade and rest, acclimatising new workers, and training workers to recognise the signs of heat illness. While there is no single temperature at which work must stop, the PCBU must demonstrate that the risk has been assessed and controls are in place.

What is WBGT and how is it used in heat stress assessment?

WBGT (Wet Bulb Globe Temperature) is an environmental heat stress index that combines the effects of air temperature, humidity, wind speed and radiant heat into a single value measured in degrees Celsius. It is defined by ISO 7243 and is the internationally recognised standard for assessing occupational heat stress. WBGT readings are compared against action limits that vary by work intensity: for moderate work, a WBGT above 28 degrees Celsius typically triggers the need for adjusted work-rest cycles, and for heavy work the threshold is lower (around 25 to 26 degrees Celsius). A WBGT monitor is the most accurate way to assess conditions, but if one is not available, air temperature and humidity can be used as a proxy.

What are the signs and symptoms of heat stroke?

Heat stroke is a life-threatening medical emergency. The key warning signs are a core body temperature above 40 degrees Celsius, hot and dry skin (sweating may or may not be present), confusion, disorientation or altered mental state, slurred speech, loss of coordination, seizures and loss of consciousness. Heat stroke can progress rapidly from heat exhaustion if early signs (heavy sweating, weakness, nausea, headache, dizziness) are ignored. If heat stroke is suspected, call 000 immediately, move the worker to a cool area, remove excess clothing and begin active cooling (cold water immersion is the most effective method, or apply ice packs to the neck, armpits and groin).

How should new workers be acclimatised to hot conditions?

New workers or workers returning after an absence of seven or more days from hot work are at significantly higher risk of heat illness because their bodies have not adapted to the heat. Safe Work Australia and NIOSH recommend a graduated acclimatisation programme: for new workers, start at no more than 50% of the normal workload or exposure time on day one, and increase by no more than 10% per day over 7 to 14 days. For workers returning after an absence, start at 50% on day one and increase by 20% per day. During acclimatisation, provide more frequent rest breaks, closer supervision and additional hydration. Monitor the worker closely for signs of heat illness throughout the acclimatisation period.

Is this heat stress risk assessment template free to download?

Yes. Download and use this heat stress risk assessment template for free. Open the file in your browser and use Print then Save as PDF. No MapTrack account is required. If you want digital heat stress assessments linked to specific work sites, with automated WBGT threshold alerts, acclimatisation tracking and trend reporting across locations, MapTrack can help. Book a demo to see how it works.

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Free heat stress risk assessment template (PDF-ready). WBGT, hydration, work-rest cycles, PPE, acclimatisation and first aid. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a heat stress risk assessment?

A heat stress risk assessment is a systematic evaluation of the factors that contribute to heat-related illness in the workplace, and the controls needed to protect workers. It examines environmental conditions (air temperature, humidity, radiant heat, wind speed), the physical demands of the work being performed, the clothing and PPE worn (which can trap heat), individual worker factors (acclimatisation status, fitness, hydration, medication) and the adequacy of existing controls (shade, ventilation, hydration stations, work-rest cycles, buddy systems and first aid preparedness). Under the WHS Act and Regulations, the PCBU has a duty to manage risks to health and safety, which includes the risk of heat-related illness when workers are exposed to hot conditions, whether outdoors in direct sun or indoors in environments such as foundries, kitchens, laundries and boiler rooms.

Heat stress is a serious and preventable risk that causes hundreds of workers compensation claims in Australia each year. Heat-related illness ranges from mild conditions such as heat rash and heat cramps through to life-threatening heat stroke, which can be fatal if not recognised and treated immediately. The risk is highest during summer in northern and central Australia, but can occur anywhere when high temperatures coincide with physically demanding work, non-breathable PPE or inadequate hydration. A structured risk assessment ensures that the specific combination of environmental, task and individual factors at a worksite are evaluated and that controls are tailored to the actual conditions, rather than relying on generic rules of thumb. MapTrack enables teams to link heat stress assessments to specific work locations and assets, record environmental readings (WBGT, temperature, humidity) over time, trigger automated alerts when conditions breach thresholds, and maintain a documented history of controls for regulatory audits.

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Benefits of using this heat stress risk assessment

Worker safety: identifies the specific combination of environmental, task and individual factors that create heat stress risk, enabling targeted controls before illness occurs.
Regulatory compliance: demonstrates that the PCBU has assessed and managed the risk of heat-related illness as required by the WHS Act and Regulations.
Reduced lost-time injuries: proactive management of heat stress significantly reduces the incidence of heat exhaustion, heat stroke and associated workers compensation claims.
Tailored controls: the assessment produces site-specific and task-specific controls (work-rest ratios, hydration schedules, shade requirements) rather than generic guidelines.
Acclimatisation management: tracks individual worker acclimatisation status, ensuring new or returning workers receive a graduated exposure plan.
Emergency preparedness: the assessment verifies that first aid resources, cool-down areas and emergency procedures are in place and understood by all workers.
Documented evidence: completed assessments provide an audit trail for regulators, clients and insurers that heat stress risks are actively managed.

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What to include in a heat stress risk assessment

This heat stress risk assessment covers 10 key areas:

Assessment details: date, time, location, assessor name, weather forecast for the day, work activity description.
Environmental conditions: air temperature (dry bulb), relative humidity, radiant heat source (direct sun, furnace, hot surfaces), wind speed, WBGT reading if a monitor is available.
Work demands: physical intensity of tasks (light, moderate, heavy, very heavy), duration of continuous physical work, frequency and duration of rest breaks, availability of shade or air-conditioned rest areas.
Clothing and PPE: type of clothing (cotton, synthetic, FR-rated), layers, colour (dark absorbs more heat), PPE requirements (hard hat, safety glasses, respirator, long sleeves, coveralls) and impact on heat dissipation.
Individual worker factors: acclimatisation status (new to hot work, returning after absence of 7+ days, fully acclimatised), fitness level, known medical conditions, medications that affect thermoregulation, pregnancy.
Hydration plan: water availability (type, location, distance from work area), recommended intake rate, electrolyte supplementation if required, signage or reminders.
Work-rest cycle: recommended work and rest durations based on WBGT or temperature and work intensity, shade or cooling available during rest periods.
First aid and emergency response: first aiders trained in heat illness recognition and treatment, cooling equipment available (ice, cold water immersion, misting fans), location of nearest emergency department or medical facility, emergency communication method.
Risk rating: overall heat stress risk for each task/location rated (low, moderate, high, extreme) based on environmental conditions, work intensity and available controls.
Controls and actions: specific control measures for each risk rating, including modified work schedules, additional hydration, buddy system, stop-work triggers, and responsible persons and review dates.

How to use this heat stress risk assessment

Review the weather forecast and environmental conditions. Measure temperature, humidity and WBGT at the work location if monitoring equipment is available.: Before workers start, check the Bureau of Meteorology forecast for maximum temperature, humidity and UV index. If your site has a WBGT (Wet Bulb Globe Temperature) monitor, take a reading at the work location during the hottest part of the planned work period. WBGT accounts for temperature, humidity, wind speed and radiant heat in a single index and is the international standard (ISO 7243) for assessing heat stress risk. If a WBGT monitor is not available, use air temperature and humidity as the primary indicators. Record the readings on the assessment form.
Assess the work tasks and physical intensity. Categorise each task as light, moderate, heavy or very heavy work, and note the planned duration and rest break schedule.: Walk through the planned work activities and categorise the physical intensity using the NIOSH/ACGIH scale: light (e.g. sitting, standing, light assembly), moderate (e.g. walking, moderate lifting), heavy (e.g. shovelling, climbing, heavy lifting) and very heavy (e.g. sustained heavy labour). Note the planned start and finish times, continuous work duration before rest breaks, and the availability and location of shade or cooled rest areas. Tasks that are normally moderate can become heavy when combined with restrictive PPE, steep terrain or elevated work positions.
Evaluate clothing, PPE and individual worker factors. Consider how each affects the body ability to cool itself and adjust the risk rating accordingly.: Non-breathable PPE, multiple clothing layers, dark-coloured garments and full-face respirators significantly reduce the body ability to dissipate heat through sweating and convection. Assess each worker acclimatisation status: workers who are new to hot work or returning after seven or more days away require a graduated exposure plan (typically starting at 50% workload and increasing over 7 to 14 days). Note any workers with medical conditions or medications that affect thermoregulation (e.g. diuretics, beta-blockers, antihistamines). These factors increase the individual risk rating above what environmental conditions alone would suggest.
Determine the heat stress risk rating for each task and location. Set work-rest cycles, hydration targets and stop-work triggers based on the rating.: Combine the environmental conditions, work intensity, clothing/PPE and individual factors to assign a risk rating. Use the WBGT action limits (from ISO 7243 or the Safe Work Australia guide) as a reference: for moderate work, a WBGT above 28 degrees Celsius typically requires adjusted work-rest cycles, and above 32 degrees Celsius may require cessation of heavy work. Set specific work-rest ratios (e.g. 45 minutes work / 15 minutes rest for moderate risk, 30/30 for high risk), hydration targets (e.g. 250 ml every 15 to 20 minutes for heavy work in high heat), and define clear stop-work triggers (e.g. WBGT exceeds a specified threshold, a worker shows signs of heat illness, ambient temperature exceeds forecast by more than 5 degrees).
Brief workers on the controls, signs and symptoms of heat illness, buddy system requirements and emergency response procedures.: Before work begins, brief all workers on the day specific controls: work-rest schedule, hydration plan, shade locations, buddy system expectations and stop-work triggers. Review the signs and symptoms of heat-related illness: heavy sweating followed by reduced or absent sweating (danger sign), headache, dizziness, nausea, confusion, slurred speech, loss of coordination and collapse. Emphasise that any worker who feels unwell must stop work immediately and notify their buddy or supervisor. Confirm that first aiders are on site, cooling equipment (ice, cold water, misting fans) is available, and the emergency communication plan is understood.
Monitor conditions throughout the work period. Re-assess if conditions change and adjust controls as required. Complete the assessment record.: Heat stress risk is dynamic. Conditions in the afternoon are typically worse than the morning. Re-take environmental readings at midday and during the hottest part of the day. Watch for early signs of heat illness in the crew. If conditions worsen beyond the original assessment (unexpected temperature spike, loss of wind, equipment failure on cooling systems), re-assess the risk rating and escalate controls, including bringing work forward to cooler hours, increasing rest frequency, or stopping work entirely. Record all re-assessments and decisions on the checklist. At the end of the work period, complete the assessment record, note any incidents or near misses, and file for future reference.

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How often should you complete this assessment?

A heat stress risk assessment should be conducted daily during hot weather periods, whenever work conditions change significantly (new location, different PPE, increased work intensity), and at the start of each summer season. The assessment should be repeated during the shift if conditions change, such as an unexpected temperature rise or a worker showing symptoms of heat illness.

Safe Work Australia's Guidance on managing the risks of working in heat recommends proactive monitoring whenever the Wet Bulb Globe Temperature (WBGT) exceeds action levels for the work intensity being performed. WHS Regulations 2011 require the PCBU to manage risks to health, including environmental heat. Organisations operating in hot climates should integrate heat stress checks into daily pre-start processes during warmer months and maintain hydration, rest-rotation and shade provisions as standard controls.

Frequently asked questions

What are the legal requirements for managing heat stress in Australia?: Under the WHS Act s19, the PCBU has a primary duty of care to ensure, so far as is reasonably practicable, the health and safety of workers. This includes managing the risk of heat-related illness. WHS Regulations Chapter 3 Part 3.1 requires the PCBU to identify hazards, assess risks and implement controls. Safe Work Australia has published a guide on managing the risks of working in heat, which recommends monitoring environmental conditions, assessing the physical demands of work, providing water, shade and rest, acclimatising new workers, and training workers to recognise the signs of heat illness. While there is no single temperature at which work must stop, the PCBU must demonstrate that the risk has been assessed and controls are in place.
What is WBGT and how is it used in heat stress assessment?: WBGT (Wet Bulb Globe Temperature) is an environmental heat stress index that combines the effects of air temperature, humidity, wind speed and radiant heat into a single value measured in degrees Celsius. It is defined by ISO 7243 and is the internationally recognised standard for assessing occupational heat stress. WBGT readings are compared against action limits that vary by work intensity: for moderate work, a WBGT above 28 degrees Celsius typically triggers the need for adjusted work-rest cycles, and for heavy work the threshold is lower (around 25 to 26 degrees Celsius). A WBGT monitor is the most accurate way to assess conditions, but if one is not available, air temperature and humidity can be used as a proxy.
What are the signs and symptoms of heat stroke?: Heat stroke is a life-threatening medical emergency. The key warning signs are a core body temperature above 40 degrees Celsius, hot and dry skin (sweating may or may not be present), confusion, disorientation or altered mental state, slurred speech, loss of coordination, seizures and loss of consciousness. Heat stroke can progress rapidly from heat exhaustion if early signs (heavy sweating, weakness, nausea, headache, dizziness) are ignored. If heat stroke is suspected, call 000 immediately, move the worker to a cool area, remove excess clothing and begin active cooling (cold water immersion is the most effective method, or apply ice packs to the neck, armpits and groin).
How should new workers be acclimatised to hot conditions?: New workers or workers returning after an absence of seven or more days from hot work are at significantly higher risk of heat illness because their bodies have not adapted to the heat. Safe Work Australia and NIOSH recommend a graduated acclimatisation programme: for new workers, start at no more than 50% of the normal workload or exposure time on day one, and increase by no more than 10% per day over 7 to 14 days. For workers returning after an absence, start at 50% on day one and increase by 20% per day. During acclimatisation, provide more frequent rest breaks, closer supervision and additional hydration. Monitor the worker closely for signs of heat illness throughout the acclimatisation period.
Is this heat stress risk assessment template free to download?: Yes. Download and use this heat stress risk assessment template for free. Open the file in your browser and use Print then Save as PDF. No MapTrack account is required. If you want digital heat stress assessments linked to specific work sites, with automated WBGT threshold alerts, acclimatisation tracking and trend reporting across locations, MapTrack can help. Book a demo to see how it works.

Applicable regulatory standards

This template aligns with the following regulations and standards:

WHS Regulations 2011 - Chapter 3 Part 3.1 (Managing risks to health and safety)
WHS Act 2011 - s19 Primary duty of care
Safe Work Australia - Guide: Managing the risks of working in heat
OSHA - NIOSH Criteria for a Recommended Standard: Occupational Exposure to Heat and Hot Environments
AS/NZS 4602 - High visibility safety garments
ISO 7243 - Ergonomics of the thermal environment (WBGT index)

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