Extreme heat is becoming a longer and more frequent operating challenge for industrial properties. EPA’s analysis of 50 major U.S. cities found that the average number of heat waves increased from two per year in the 1960s to six per year in the 2020s. The average heat-wave season is now 46 days longer, and the average heat wave has increased from about three days to four. EPA also found that heat waves in the 2020s are more intense than those measured in the 1960s.

For industrial property managers, the concern extends beyond outdoor temperatures. Prolonged heat places additional demand on cooling equipment, increases electrical loads, raises roof and pavement temperatures and can create difficult working conditions inside facilities that generate heat through manufacturing processes, equipment or material handling.

The best time to find weaknesses in a building’s response to heat is before the next extended hot-weather period.

Start With the Cooling System

HVAC equipment is usually the first building system to feel the pressure of sustained heat. Rooftop units and other cooling equipment may operate for longer periods and at higher loads, leaving less opportunity for components to recover between cycles.

The U.S. Department of Energy recommends preventive maintenance for commercial HVAC systems because proper operation and maintenance can improve efficiency, reduce failures and extend equipment life. DOE estimates that organizations can save 5% to 20% annually on energy costs through operations and maintenance best practices.

Before the hottest part of the year, property managers should have HVAC contractors inspect coils, filters, fans, belts, motors, electrical connections, condensate systems, refrigerant charge and controls. Condenser and evaporator airflow deserves particular attention. DOE research identifies insufficient airflow and fouled heat-transfer surfaces as conditions that can reduce cooling capacity and efficiency. Refrigerant leaks and improper refrigerant charge can also reduce capacity and increase operating stress.

Controls should be included in the inspection. Economizers, dampers and sensors can affect how a rooftop unit responds to outdoor conditions. DOE notes that a failed economizer damper can introduce warm outdoor air during cooling operation or restrict required ventilation when it remains closed.

Older rooftop units deserve particular scrutiny. DOE has identified units more than 15 years old as a common source of reduced service and wasted energy and recommends evaluating proactive replacement when older equipment is inefficient or underperforming.

For an industrial property, that assessment should include more than the age of the equipment. Maintenance history, repair frequency, available replacement parts, cooling capacity and the importance of the areas served should factor into the decision to repair or replace a unit.

Inspect the Roof Before the Heat Arrives

Industrial roofs absorb substantial solar heat during the summer. EPA notes that conventional roofing materials can reach temperatures as much as 66°F above surrounding air temperatures, depending on conditions.

That makes the roof one of the most exposed parts of an industrial building during prolonged heat.

A pre-summer roof inspection should document membrane condition, seams, flashing, penetrations, drainage, rooftop equipment curbs and areas where previous repairs have been made. Property managers should pay particular attention to equipment and maintenance work that may have disturbed the roof system.

Drainage also matters during summer heat events because extreme heat frequently coincides with severe thunderstorms in many parts of the country. Drains, scuppers and gutters should be clear before the season begins, and roof inspections should identify areas where ponding has occurred.

Reflective roofing can also reduce heat absorption. EPA describes cool roofs as systems designed to reflect more solar energy and release absorbed heat more effectively. They can reduce roof and indoor temperatures and lower air-conditioning demand.

For an existing property, the decision to install a cool roof or reflective coating should be evaluated alongside the roof’s remaining service life, membrane compatibility, warranty requirements and planned replacement schedule.

Watch Electrical Equipment During Peak Loads

Heat also changes the operating environment for electrical infrastructure.

Cooling equipment increases electrical demand during hot weather, while transformers, switchgear and other electrical equipment may already be operating under significant load. Heat generated inside electrical equipment has less opportunity to dissipate when surrounding temperatures are elevated.

The property team should review electrical maintenance records before summer and identify equipment with recurring breaker trips, overheating, failed components or other reliability issues. Infrared thermography can be particularly useful for identifying abnormal temperature patterns at connections and components while equipment is operating.

The inspection should be performed under representative load conditions and documented so that results can be compared with future scans. Any significant thermal anomaly should be evaluated by qualified personnel to determine the cause and appropriate corrective action.

This is especially important in older industrial buildings where electrical systems may have been modified repeatedly as tenant operations changed. A new production line, refrigeration system, automation equipment or other large load can alter the demands placed on distribution equipment that may already be several decades old.

The property’s electrical maintenance program should therefore account for both equipment condition and current tenant loads.

Pay Attention to Pavement and Site Conditions

Industrial sites can experience substantial surface temperatures during periods of extreme heat. EPA cites an Arizona pilot study in which conventional paving materials reached surface temperatures as high as 152°F around midday. Cool pavement surfaces in the same study were 10°F to 16°F cooler.

For property managers, pavement inspections should focus on cracking, joint deterioration, failed sealants, localized settlement and areas that experience heavy truck traffic. Extreme temperatures can compound deterioration that is already underway.

Loading docks and paved areas deserve particular attention because failures in these locations affect both building access and tenant operations. A damaged section of pavement can interfere with trailers, forklifts, drainage and pedestrian routes.

The inspection should also include exterior equipment pads, dock levelers and other site infrastructure exposed to direct sun. Repairs that require sealants, coatings or other temperature-sensitive materials should follow manufacturer requirements for installation conditions.

Protect Employees Working in and Around the Building

Heat management also extends beyond building equipment. Industrial properties can contain indoor areas with high heat loads from manufacturing equipment, ovens, boilers, process equipment or other sources. Warehouses and loading areas may also become significantly hotter than conditioned office space.

OSHA identifies industrial environments such as foundries, bakeries, laundries, food canneries, chemical plants, electrical utilities and other facilities as settings where heat stress can occur. Heat exposure depends on more than air temperature; humidity, radiant heat, air movement, physical activity and clothing can all affect worker exposure.

OSHA’s 2026 National Emphasis Program for heat-related hazards directs inspection and outreach resources toward 55 high-risk industries using OSHA and Bureau of Labor Statistics data from 2022 through 2025. The program covers both indoor and outdoor workplaces.

Property managers should coordinate with tenants before a prolonged heat event to clarify responsibilities for common areas, loading docks, building systems and emergency communications. Tenants remain responsible for their workplace safety programs, but building conditions can contribute directly to heat exposure.

OSHA recommends engineering controls such as air conditioning, ventilation, cooling fans and local exhaust ventilation, along with work-practice controls such as modified schedules and rest periods when heat exposure cannot be adequately controlled through engineering measures.

Identify the Buildings Most at Risk

Every industrial building responds differently to heat. A refrigerated warehouse, manufacturing facility and conventional distribution center can have very different cooling requirements and failure consequences.

Property managers should identify the systems and areas where a failure during extreme heat would have the greatest operational impact. That assessment should consider the age and condition of HVAC equipment, electrical infrastructure, refrigeration, building envelope, roof systems and tenant operations.

Equipment serving critical areas should receive priority for preventive maintenance. Spare parts and replacement equipment should also be considered for older systems with long lead times.

DOE’s guidance on HVAC commissioning emphasizes verifying that systems operate according to their design criteria and notes that commissioning can uncover faulty equipment and control problems that affect energy use and comfort.

For older industrial properties, a targeted commissioning or functional performance review can be useful when a building repeatedly struggles to maintain conditions during peak summer loads. The goal is to determine whether the problem originates with equipment capacity, controls, airflow, maintenance or the building’s underlying design.

Make Heat Preparation Part of the Maintenance Calendar

Extreme heat should be incorporated into the property’s regular maintenance planning rather than handled only when temperatures rise.

Several weeks before the expected peak cooling season, property teams can review HVAC service records, inspect roof and drainage conditions, assess electrical equipment with known reliability issues and identify areas where tenant operations create additional heat. During prolonged heat events, maintenance teams can monitor equipment alarms, tenant complaints, energy consumption and HVAC runtime for signs of declining performance.

Energy use can provide another useful signal. A significant increase in cooling demand without a corresponding change in occupancy or weather conditions may warrant investigation of equipment performance, controls or building envelope conditions.

The EPA recommends that building owners inspect cooling equipment and perform monthly maintenance during summer.

The objective is to enter the hottest part of the year with known equipment conditions, documented deficiencies and a response plan for systems that fail under load. For industrial properties, that preparation protects more than occupant comfort. HVAC, electrical, roofing, refrigeration and site infrastructure all support tenant operations, and prolonged heat can expose weaknesses across each of them.

As extreme heat becomes a more frequent part of the operating environment, property managers have a growing reason to treat summer readiness as an annual building-maintenance priority. The most useful preparation begins with the equipment already in the building, its maintenance history and the conditions it will be expected to handle.

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