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Climate-related increases in global mean temperature and the intensification of heat waves present a significant threat to outdoor workers. Limited research has been completed to assess the potential differences in heat exposures that exist between individuals within similar micro environments. Yet, there is a paucity of individual data characterizing patterns of individually experienced temperatures in workers and the associated physiologic heat strain response. The objective of this study was to apply a wearable sensor-based approach to examine the occupational, environmental, and behavioral factors that contribute to individual-level variations in heat strain in grounds maintenance workers. Outdoor workers from three diverse climatic locations in the southeastern United States - high temperature, high temperature + high humidity, and moderate temperature environments - participated in personal heat exposure monitoring during a 5-day work period in the summer. We performed Cox proportional hazards modeling to estimate associations between multiple heat strain events per worker and changes in individually experienced temperatures. Heat strain risk was higher among workers with a place to cool-off, higher education, and who worked in hotter temperatures. A mismatch was observed between workers' perceptions of heat strain and actual heat strain prevalence across exposure groups. We also used a quasi-Poisson regression with distributed lag non-linear function to estimate the non-linear and lag effects of individually experienced temperatures on risk of heat strain. The association between increasing temperature and heat strain was nonlinear and exhibited an U-shaped relationship. Heat strain was less common during issued heat warnings demonstrating behavioral adaptive actions taken by workers. This study is one of the first temperature monitoring studies to quantify the individual-level exposure-response function in this vulnerable population and highlights the elevated risk of heat strain both immediately and several days after worker exposure to high temperatures.