Hydration

Heat stress and worksite hydration

Heat-related illness is a recognised WHS hazard in Australian workplaces. Under Safe Work Australia's Managing the risks of working in heat guidance, employers must provide cool water, electrolyte replacement, shaded rest areas, and work-rest cycles scaled to the heat load. For outdoor trades, mining, construction, emergency services, and any workforce exposed to temperatures above 28 °C, plain water is insufficient — sustained sweating depletes sodium, potassium, and magnesium, and electrolyte drinks are the practical countermeasure.

Why electrolytes matter

Heavy sweating in heat strips the body of sodium and other electrolytes at a faster rate than they can be replaced by food and water alone. Symptoms of hyponatremia (low blood sodium) — headache, cramping, nausea, confusion — often present as "dehydration" on site, leading workers to drink more water, which worsens the imbalance. Electrolyte drinks replace what's lost in sweat at the right ratio to keep blood sodium stable through a full shift.

The Aqualyte range

Aqualyte is an Australian-made electrolyte drink mix formulated for occupational heat-stress environments — lower in sugar than sports drinks, with a salt profile matched to industrial sweat rates. Supplied across the formats workplaces actually use: individual sachets for crib-bag distribution, tubs for shared stations, and ready-made icy poles for rapid cooling.

• 25 g sachets — mix into a 600 mL bottle or hydration-pack bladder. Individual-issue, portable, the workhorse format. Browse 25 g sachets →
• 80 g sachets — mix into a 2 L bottle or larger hydration bladder. For extended shifts and high-sweat-rate work. Browse 80 g sachets →
• 800 g sachets — shared-station format for crib rooms, shift start-ups, and multi-worker dispensing. Browse 800 g sachets →
• 480 g tubs — home-issue or small-team tub with scoop. Browse 480 g tubs →
• Icy poles — pre-frozen Aqualyte icy poles for core-temperature reduction during rest breaks. Rapidly lowers core temp and replaces electrolytes in one step. Browse icy poles →
• Promotional products — branded bottles, bladders, and co-branded sachet boxes for workforce hydration programs. Browse promotional →

How much to provide

Worker sweat rates in hot conditions commonly reach 1–1.5 L/hour, occasionally higher. Safe Work Australia recommends 600 mL–1 L per hour for moderate heat and higher for intense work or extreme heat. A typical industrial deployment plans for one 25 g sachet per worker every 600 mL–1 L drunk, with free access to water alongside. Crib-room 800 g sachets cover 10–15 workers for a shift. Icy poles are issued 1–2 per worker during scheduled rest breaks.

Sugar, caffeine, and compliance

Aqualyte is deliberately lower in sugar than sports drinks (typical sports drinks are 6–8% sugar; Aqualyte is around 3%) to avoid the gastrointestinal upset and energy crashes that high-sugar formulations cause on long shifts. It contains no caffeine or stimulants. Vegan and gluten-free; suitable for workforce-wide rollout without individual dietary screening.

Heat-stress management — beyond the drink

Providing Aqualyte is one control — under a compliant heat-management plan it sits alongside:

• Work-rest cycles adjusted to WBGT (wet-bulb globe temperature).
• Shaded or air-conditioned rest areas.
• Urine-colour charts or hydration self-assessments.
• Acclimatisation programs for new workers (10–14 days to adapt to heat).
• Supervisor training in early heat-illness recognition.

Standards & compliance

Aqualyte products comply with Food Standards Australia New Zealand (FSANZ) food-safety requirements. Labelling includes ingredient disclosure, nutritional information, and AU/NZ manufacture origin. Workplace hydration programs should align with the Safe Work Australia Managing the risks of working in heat guide and relevant industry-specific guidance (mining, construction, agriculture).

Frequently asked questions

How many sachets per worker per shift?

For moderate-heat outdoor work, plan for 4–6 × 25 g sachets per worker per 8-hour shift (mixed with 2.4–3.6 L of water). For high-sweat-rate work (hot climates, heavy physical load, mining), step up to 6–10 sachets. Icy poles are issued at structured rest breaks, not as a sachet replacement.

Is plain water enough if the worker is drinking plenty?

No — on hot-weather long shifts, heavy water intake without electrolyte replacement can cause hyponatremia. Symptoms (headache, cramping, nausea, confusion) look like dehydration, often leading to more water intake and a worsening cycle. Electrolyte drinks stabilise blood sodium.

Can Aqualyte be mixed into hydration-pack bladders?

Yes — 25 g per 600 mL bladder, 80 g per 2 L bladder. Clean the bladder regularly (at least weekly); electrolyte mixes leave residue that can grow microbial contamination if bladders aren't washed between uses.

Do you offer trade or bulk pricing?

Yes — trade accounts receive 5% off RRP on Aqualyte, and site programs (mining, civil construction, emergency services) qualify for case-quantity bulk pricing. Promotional products with workplace branding available with minimum-order quantity. Apply for a trade account →