BACKGROUND: Exertional heatstroke affects athletes and soldiers and can lead to temporary heat intolerance. The heat tolerance test (HTT) was developed to assist in the return-to-duty decisions of military personnel. Although there are several possible causes for heat intolerance, a soldier who fails the test is prevented from returning to serve in a front-line combat unit, regardless of the underlying reason.CASE REPORT: A 19-yr-old special infantry male soldier with unremarkable medical history collapsed during an afternoon hand-to-hand combat training session in the gym. The medic on site promptly initiated inefficient tap water cooling and measured a rectal temperature of 38.7 °C; he returned to duty the same evening. A few weeks later, after intensive physical training, he experienced exhaustion during a stretcher-carrying foot march. He was referred by the unit's physician, who suspected a condition of heat intolerance, to an HTT. The soldier underwent two HTTs, which were found to be positive. Consequently, he was discharged from serving in his infantry unit. No congenital or functional underlying causes could explain the diagnosis of heat intolerance.DISCUSSION: We discuss the possibility that the only explaining cause for the two positive HTTs was the soldier's anthropometric measures, particularly the low body surface area to body weight ratio. We raise the question of whether this soldier could have been returned safely to duty.Rabotin A, Epstein Y, Ketko I. Heat intolerance, body size, and return to duty. Aerosp Med Hum Perform. 2023; 94(7):546-549.