Safety & Compliance · SOP

Cold Storage Warehouse Worker Thermal Ppe Guidelines

Comprehensive standard operating procedure for selection, daily inspection, donning, doffing, and maintenance of personal protective equipment (PPE) for workers exposed to cold storage environments (−20 °C and below). Complies with CSA Z94.1, CSA Z94.4, and WorkSafeBC OHS Part 8.

Estimated Time

15 min

Difficulty

Intermediate

Regulation

CSA Z94.1

Version

1.0

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Purpose

To establish a standardized process for the selection, daily inspection, correct donning/doffing, and routine maintenance of thermal protective equipment in cold storage warehouses. This procedure reduces the risk of cold‑stress injuries (frostbite, hypothermia) and ensures compliance with applicable health and safety regulations. All personnel entering freezer zones (≤ −20 °C) must follow these steps without deviation.

Scope

Applies to all warehouse employees, supervisors, and visitors required to enter cold storage areas (freezer rooms, cold docks, and refrigerated corridors) where ambient temperature is at or below −10 °C. Excludes personnel using temporary warm‑up breaks for less than 5 minutes. This document covers full‑body thermal PPE only; respiratory protection is covered under a separate SOP (see Related Documents).

Safety Precautions

FROSTNever wear metal jewellery or glasses with metal frames — they conduct cold and can freeze to skin. Remove all rings, earrings, and watches before donning.
TIMEExposure time in −20 °C zones is limited to 30 continuous minutes without a 10‑minute warm‑up break in a controlled environment (> 10 °C). Use a timer or buddy watch system.
LONENo lone work in freezers below −15 °C. Always use a two‑person rule or a thermal alarm. If you feel numbness, shivering, or disorientation, exit immediately.
WETDo not enter cold storage if your clothing is damp from sweat or moisture — wet insulation loses thermal value and accelerates heat loss. Change into dry base layer before entry.

Required Tools & Materials

Thermal insulated coverall – CSA Z94.1 certified, minimum 200 g/m² insulation
Insulated outer gloves with moisture barrier (e.g., polyurethane‑coated nylon)
Thermal liner gloves (fleece or merino wool) for inner layer
Balaclava or insulated hood (wind‑resistant fabric)
Steel‑toed insulated boots – rated for −30 °C, slip‑resistant outsole
Anti‑fog safety glasses (CSA Z94.3 – impact/dust rated)
Hi‑visibility vest or jacket (if required by facility traffic zone)
PPE inspection checklist (digital form or laminated card)
Designated locker or drying area for storage and ventilation

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Procedure: Step-by-Step

1 Pre‑donning inspection. Examine coverall for tears, broken zippers, or insulation clumping. Check gloves for pinholes or delamination. Verify boot tread depth ≥ 3 mm and insulation intact. Use the visual inspection checklist (Appendix A). Discard any defective item and tag for replacement.

2 Base layer preparation. Remove all jewellery. Put on a dry moisture‑wicking base layer (polypropylene, merino, or silk). Never wear cotton next to skin. Ensure base layer is snug but not restrictive. Add mid‑layer (optional) if temperature is below −25 °C.

3 Donning sequence. (a) Pull on thermal liner gloves, then outer gloves – ensure overlap with sleeve cuff. (b) Place balaclava, tuck neck tail into collar. (c) Step into coverall, fasten zipper fully from bottom to top, close storm flap. Secure wrist and ankle straps. (d) Put on boots, lace all eyelets, tuck cuff into boot shaft. (e) Position safety glasses over hood, adjust nose bridge for fog prevention. (f) Add hi‑vis vest if required by traffic management plan.

4 Mobility check. Raise arms overhead, squat to knee – 90°, rotate torso left and right. Ensure no binding at shoulders, groin, or knees. Walk 10 m in the staging area. Adjust any straps or closures that restrict movement. Re‑inspect for gaps at wrists, ankles, and neck.

5 Enter cold storage. Use the transition vestibule: wait 2 minutes at −10 °C before moving into the −20 °C freezer. Buddy up – confirm your partner is also properly dressed. Start a timed exposure log (max 30 min). If you feel any pain, numbness, or shivering, signal your buddy and exit to warm‑up room.

6 Doffing and aftercare. In the designated warm area (≥ 10 °C): remove gloves first (turn inside out to shed condensation). Unzip coverall from top, peel off upper half, then lower half. Hang coverall on insulated hanger with zipper open to air‑dry. Remove liners and boots – place boots on drying rack designed for insulated footwear. Do not store damp PPE in a sealed bag. Report any moisture or damage to supervisor immediately.

Cold Storage Warehouse Worker Thermal Ppe Guidelines

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