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2024 U.S. Confined Space Report Insights

Posted on by Robin Walters

The 2024 U.S. Agricultural Confined Space-related Injuries and Fatalities Report from Purdue University highlights the persistent dangers faced by workers in agricultural confined spaces. With a total of 2,429 documented cases to date, nearly 60% of which have been fatal, the need for heightened safety measures and awareness remains critical across the industry.

Key Findings

24 Confined Space Report from Purdue University

This year’s summary reveals several important statistics and trends:

  • 51 confined space-related incidents were recorded in 2024, marking a 7% decrease from 2023, but still highlighting significant safety concerns.
  • 34 grain-related entrapments, representing a 25% increase from 2023, continue to be the leading cause of incidents.
  • There were three fatalities in livestock waste storage pits or lagoons, and four fatalities linked to vertical and tower forage silo incidents.
  • Nine additional grain dust explosions occurred, thankfully without fatalities, but underscoring the potential risks in grain handling environments.
  • 22 fatalities were reported in 2024, which represents 43% of the total incidents—lower than the historical average of 58%.
  • OSHA Regions 5 and 7 historically account for about 68% of documented confined space-related incidents.

In addition, the report notes a continued focus on emergency responder training, which has shown some improvement but remains somewhat limited in its effectiveness due to the low frequency of these events and the unfortunate reality that many victims pass away before help arrives.

The Ongoing Need for Enhanced Safety Measures

While emergency response training is essential, the report highlights that prevention is the most effective way to reduce the risk of these incidents. The increase in grain entrapments and dust explosions emphasizes the need for proactive safety measures that focus on grain quality and hazard identification.

Preventing Grain Entrapment and Other Incidents

The report stresses that the key to preventing grain entrapment incidents lies in proper grain handling and monitoring during storage. Preventive measures, including maintaining equipment in good condition, regular inspections, and safe work practices, are critical to avoiding hazardous situations. Additionally, it’s essential to provide adequate training to employees and emergency responders, focusing on recognizing hazards early and taking appropriate action.

The Importance of Ongoing Safety Efforts

The 2024 Purdue report serves as a stark reminder of the dangers present in agricultural confined spaces, particularly in grain storage and handling facilities. Despite the improvements in some areas, the overall number of incidents remains a significant concern. The focus must remain on preventive safety measures such as proper maintenance, training, and awareness to reduce the risk of entrapment and other incidents.

At Safety Made Simple, we are committed to supporting agricultural operations with the training and resources needed to protect workers from these life-threatening hazards. Test drive these applicable courses for free:


Learn more about how we can help you implement safer practices and stay compliant with industry standards by scheduling a free assessment for your company. Do your part in lowering the occurrences of incidents and accidents in confined spaces.

2024 U.S. Dust Explosions Report

Posted on by Robin Walters

According to the 2024 Agricultural Dust Explosions Report by Purdue University, there were nine grain dust explosions reported in the U.S. this year, which is consistent with the previous year and aligns with the ten-year national average of 8.6 explosions. Fortunately, no fatalities occurred, but the explosions resulted in two injuries. These incidents took place in a variety of facilities, including feed mills, grain elevators, ethanol plants, and a corn processing plant.

Key Findings

  • Ignition Sources: The probable ignition sources for these explosions were:
    • Two cases: smoldering grain
    • Two cases: equipment malfunction
    • One case: welding work
    • One case: cutting work
    • Three cases: unknown
  • Fuel Sources: The fuel sources for the explosions were primarily:
    • Grain dust: 6 incidents
    • Smoldering grain: 2 incidents
    • Smoldering feed: 1 incident
  • Geographic Distribution: The nine explosions occurred in varying states. They occurred in Illinois, Iowa, Kansas, Michigan, Minnesota, Nebraska, North Carolina, Tennessee, and Wisconsin.

While these numbers show no increase in fatalities or a significant rise in injuries, Kingsly Ambrose, Purdue University professor of agricultural and biological engineering, notes that the damage caused by these explosions—including downtime, repair costs, and potential litigation—can be substantial. It’s important to note that even low-magnitude explosions can still cause significant disruption to operations.

Prevention: Proactive Measures for Grain Storage Safety

The key to preventing grain dust explosions lies in maintenance, housekeeping, and proper handling of grain throughout the season. Here are a few critical tips from Ambrose to prevent such accidents:

  1. Pre-Harvest Equipment Maintenance
    Preventive maintenance is essential before the harvest or handling season begins. Inspect equipment for any potential issues, such as belt misalignment in bucket elevators, which can cause friction and heat generation—an increased risk for dust explosions. Check out our courses on preventative equipment maintenance:
    Bucket Elevator: Components & Operation
    Bucket Elevator: Maintenance
    Dust Collector: Maintenance
    Belt Conveyors: Maintenance
    Screw and Chain Conveyors: Maintenance
    Grain Dryers: Maintenance
    Grain Dust Explosions: Prevention
  2. Aeration and Storage Conditions
    Once grain is harvested, maintaining the proper aeration in storage bins is critical to reduce the risk of smoldering grain. Improper aeration can lead to fungal growth, which in turn can cause the grain to smolder, increasing the chances of a dust ignition. To better understand how grain can be explosive under the right conditions, check out our course Grain Dust Explosions: The Chain Reaction.
  3. Housekeeping is Key
    Proper housekeeping is one of the most effective ways to prevent explosions and safeguard employee health. Ensure there is no visible settled dust in the facility and that suspended dust in the air is minimized. Dust accumulation, whether it’s in storage bins or on machinery, significantly raises the risk of an explosion. For more information, check out our course Housekeeping and Combustible Dust.
  4. Regular Inspections
    Conduct regular inspections and clean the facility often. Equipment should be checked for wear and tear, and any signs of malfunction should be addressed immediately. Take the time to ensure that dust collection and monitoring systems are functioning properly and that grain handling equipment is in good working condition. We offer a course on Hazard Monitoring Equipment.

Proactive Steps Save Lives

While 2024’s report shows a stable number of incidents, it’s a reminder that vigilance and proper preventive measures are crucial in avoiding grain dust explosions. Preventive maintenance, safe grain storage practices, housekeeping and regular inspections/maintenance can make a significant difference in protecting workers, facilities, and the surrounding community from the devastating effects of dust explosions.

For more in-depth training on maintaining a safe work environment, Safety Made Simple offers courses that can help you implement the right practices to keep your team safe and compliant. Explore our training catalog!

Simple and Effective Onboarding: An SMS Success Story

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Onboarding new employees is a critical yet challenging step for any organization—particularly when it comes to safety. Bringing someone up to speed on the potential risks, policies, and procedures is essential, and it can be overwhelming if you’re trying to cover everything at once. Fortunately, with the right strategies, tools, and team in place, you can streamline the onboarding process and ensure that every new hire starts their journey ready to work safely and effectively.

A Real-World Success Story
We recently sat down with Dean Alling, People Operations Director at Ray Carroll County Grain Growers Inc, who shared his experience using Safety Made Simple as part of his organization’s onboarding process. According to Dean,

“Safety Made Simple is an awesome tool to help make sure our guys are going home safely every day. We set up learning paths in the Safety Made Simple system so that our people are on-boarded properly. They are introduced and trained on those hazards before they’re introduced to the risk.”

By assigning courses that cover key hazards in the grain industry—like combustible dust, lockout/tagout, and safe grain bin entry—Dean’s team ensures new hires aren’t blindsided by unfamiliar risks. This proactive approach sets a clear tone for safety from day one, reinforcing the importance of protecting employees’ well-being.

Why Onboarding Matters
As Safety Made Simple’s Joe Mlynek points out in his work on employee onboarding, you need to define clear goals for new hires—what they should learn, the skills they need to master, and the responsibilities they’ll be expected to handle. This goes beyond just compliance. It’s about giving employees the knowledge and resources to perform their roles confidently and safely. A well-structured onboarding plan:

  1. Clarifies Expectations – Employees should know what’s expected of them in terms of productivity, safety, and teamwork.
  2. Builds a Team Approach – Involve HR, operations, safety professionals, and senior management to identify the critical tasks and hazards.
  3. Leverages the Right Tools – Learning management systems (LMS), safety management platforms, and HRIS solutions can centralize training, testing, and tracking.
  4. Uses Effective Delivery Methods – Blend face-to-face instruction, online courses, hands-on practice, and group discussions to reinforce retention.
  5. Phases in Learning – Spread training over the first weeks or months so employees aren’t overloaded.

Setting the Stage for Success
A phased onboarding approach is especially valuable in high-risk industries like agriculture and grain handling. Rather than rushing new hires into complex tasks, start them with lower-exposure activities and gradually introduce higher-risk responsibilities as their competence grows. Consider pairing them with seasoned mentors who lead by example and can offer real-time coaching and feedback.

By combining Safety Made Simple’s engaging, concise online courses with hands-on training, demonstrations, and mentorship, new employees at Ray Carroll County Grain Growers are consistently introduced to hazards before they’re exposed to them on the job. This blend of passive (online, classroom)) and participatory (group discussion, practice) learning has proven highly effective, improving knowledge retention and reinforcing safe behavior.

Commitment Counts
New employee onboarding shouldn’t be a race or a box-checking exercise—it’s an investment in your workforce and your organization’s culture of safety. As Dean Alling’s experience shows, starting strong with tailored, relevant training ensures that every new hire is prepared to identify and handle workplace hazards confidently from day one. When you define clear goals, assemble the right team, and use an LMS or HRIS effectively, onboarding becomes a strategic advantage rather than a hurdle.

If you’re ready to enhance your onboarding process and create a safer workplace, reach out to Safety Made Simple. We can help your organization build learning paths that align with your operational hazards, ensuring your people gain the skills they need before they face the risk. Here’s to sending everyone home safely—every day.

Anhydrous Ammonia Safety: Protect Workers and Prevent Hazards

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As we approach the spring season, many agricultural retailers are preparing their teams for another busy year. One key area of focus is the safe handling and transportation of anhydrous ammonia (NH3), a widely used nitrogen fertilizer. However, working with anhydrous ammonia presents significant hazards that require strict adherence to safety protocols and proper personal protective equipment (PPE).

Anhydrous ammonia is one of the most dangerous chemicals used in agriculture today, and proper training is essential to reduce the risks associated with handling and transporting it. As North Dakota State University’s Ag Machine Systems Specialist John Nowatzki explains, the majority of accidents related to anhydrous ammonia stem from uncontrolled releases—often caused by improper procedures, untrained workers, or faulty equipment. Fortunately, safe practices, proper PPE, and well-maintained equipment can greatly reduce these risks.

Anhydrous Ammonia Safety

Key Hazards of Anhydrous Ammonia

Anhydrous ammonia is a colorless gas that has a very distinct, pungent odor. It is stored under high pressure, which allows it to be transported and used efficiently. However, the gas can be hazardous when mishandled:

  • Skin and Eye Exposure: Anhydrous ammonia freezes on contact with skin, causing chemical burns and permanent tissue damage. It can also severely damage the eyes, potentially causing blindness.
  • Inhalation: The fumes can irritate and burn the respiratory system. At high concentrations, ammonia exposure can be fatal.
  • Pressure Risks: Ammonia is stored at pressures of 250 psi or more, which can cause violent ruptures and releases of ammonia, making safety during storage and transport a top priority.

Protective Equipment Requirements

To handle anhydrous ammonia safely, protective equipment must always be available where ammonia is being applied or transported. OSHA requires that employers provide the necessary PPE to protect workers from potential exposure. Protective gear greatly reduces the chances of injury from an ammonia release. The following PPE is critical for anyone working with anhydrous ammonia:

  1. Goggles: Unvented goggles are essential for protecting the eyes from ammonia exposure. Pesticide-type vented goggles will not suffice, as ammonia can pass through the vents.
  2. Gloves: Rubber gloves that are resistant to ammonia should be worn. The gloves should have long cuffs to prevent ammonia from running down the arms during handling.
  3. Respirators: Respirators with ammonia-specific cartridges are required for exposure to ammonia vapors. For high-level exposures, a self-contained breathing apparatus (SCBA) is necessary.
  4. Protective Clothing: Heavy-duty, tightly woven fabric clothing should be worn to protect the skin from ammonia exposure. Avoid lightweight fabrics, as ammonia can easily penetrate them.

Best Practices for Safe Handling

When working with or around anhydrous ammonia, it is vital to follow the correct procedures and take safety precautions. Here are some best practices for working with NH3 in the field:

  • Always wear gloves and goggles when connecting or disconnecting tanks.
  • Always have backup PPE on hand, including a second pair of gloves, goggles, a respirator with an approved cartridge, and 5 gallons of fresh water for emergency flushing.
  • Ensure you always work upwind of ammonia equipment to avoid inhaling fumes.
  • When transporting ammonia, always carry the hose by the valve body to prevent damage to the valve or seals.
  • Use the proper procedures for connecting and disconnecting nurse tanks and applicators to minimize exposure risks.

Training and Certification

Proper training is critical to ensuring safety when working with anhydrous ammonia. Safety Made Simple offers two specialized courses focused on anhydrous ammonia safety:

  1. Anhydrous Ammonia: General Awareness: This course provides an overview of the hazards associated with anhydrous ammonia and the required safety procedures for handling it.
  2. Anhydrous Ammonia: Use & Transportation in Agriculture: Focused on the safe use and transportation of anhydrous ammonia, this course covers proper storage, handling techniques, and emergency response strategies.

Both courses are designed to give agricultural workers the knowledge and skills they need to stay safe while working with this hazardous substance.

As spring approaches and anhydrous ammonia is prepared for application, it’s crucial to ensure that workers are properly trained and equipped to handle the risks. By following safe practices, using the right protective equipment, and ensuring that employees are fully trained, we can help reduce the likelihood of ammonia-related accidents and keep workers safe.

OSHA Top 10 Cited Standards in 2024

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The Occupational Safety and Health Administration (OSHA) released its preliminary data for 2024, revealing the most frequently cited standards in the workplace. While some of these standards remain constant year over year, their relevance to protecting workers cannot be overstated. As OSHA’s Director of Enforcement Programs, Scott Ketcham, pointed out, these violations have led to preventable tragedies. It is vital that employers take these citations seriously and ensure compliance with the necessary safety protocols.

OSHA Top 10 Cited Standards

In this post, we’ll explore the top 10 most cited OSHA standards, along with the associated courses offered by Safety Made Simple to help your team stay compliant, reduce risks, and improve workplace safety.

1. Fall Protection – General Requirements (1926.501)

Total Violations: 6,307
Most Cited Section: 1926.501(b)(13) – Residential construction activities 6 feet or more above lower levels shall be protected by guardrail systems, safety net systems, or personal fall arrest systems.

Safety Made Simple Training Courses:
Fall Arrest and Restraint Protection
Fall Protection Introduction to Fall Arrest and Restraint
Railcar Fall Protection Training
Fall Protection Working at Heights

For the 14th consecutive year, Fall Protection remains the most frequently cited violation. Fall-related injuries are one of the leading causes of workplace fatalities. Our Fall Protection Training courses cover the necessary precautions and safety systems required to prevent falls and protect employees working at heights.

2. Hazard Communication (1910.1200)

Total Violations: 2,888
Most Cited Section: 1910.1200(e)(1) – Employers must develop, implement, and maintain a written hazard communication program.

Safety Made Simple Training Courses:
Hazard Communications Safety Data Sheets
Hazard Communication Labels and Pictograms

With chemicals present in nearly every industry, proper hazard communication is essential. These Hazard Communication courses help employers ensure that workers understand the chemicals they are working with and have access to the necessary Safety Data Sheets (SDS) and labels.

3. Ladders (1926.1053)

Total Violations: 2,573
Most Cited Section: 1926.1053(b)(1) – When portable ladders are used for access to an upper landing surface, the ladder must extend at least 3 feet above the upper landing surface.

Safety Made Simple Training Courses:
Three Point Rule Preventing Slips and Falls
Portable Ladders

Ladders are ubiquitous in construction and other industries, but improper use can lead to serious accidents. Our Ladder Safety courses provide essential training on safe ladder practices, including how to inspect and use ladders properly to avoid falls and injuries.

4. Respiratory Protection (1910.134)

Total Violations: 2,470
Most Cited Section: 1910.134(e)(1) – Employers must provide a medical evaluation to determine employees’ ability to use a respirator.

Safety Made Simple Training Courses:
Air Purifying Respirators
Particulate Respirators

Respiratory hazards are a common issue in industries like construction and manufacturing. Our Respiratory Protection courses cover the essentials of selecting, maintaining, and using respirators to ensure employees are properly protected from airborne contaminants.

5. Lockout/Tagout (1910.147)

Total Violations: 2,443
Most Cited Section: 1910.147(c)(4) – Energy control procedure must be established for servicing and maintenance.

Safety Made Simple Training Courses:
Lockout Tagout When in Doubt, Lock and Tag it Out
Lockout Tagout the Basics
Lockout Tagout Complex Procedures

Lockout/Tagout procedures are crucial to prevent machinery from being accidentally energized during maintenance. Our Lockout/Tagout Safety courses teach employees how to properly isolate hazardous energy and prevent accidents during service or repair.

6. Scaffolding (1926.451)

Total Violations: 1,873
Most Cited Section: 1926.451(g)(1) – Employees on scaffolds more than 10 feet above a lower level must be protected from falling.

Safety Made Simple Training Courses:
Scaffolding Safety

Scaffolding is a common and necessary tool in construction, but it poses risks if not properly assembled and used. Our Scaffolding Safety course covers safe practices for erecting, using, and inspecting scaffolding to ensure workers are protected at heights.

7. Personal Protective and Lifesaving Equipment – Eye and Face Protection (1926.102)

Total Violations: 1,814
Most Cited Section: 1926.102(a)(1) – Employers must ensure that affected employees use appropriate eye or face protection.

Safety Made Simple Training Courses:
PPE Basics
PPE Eye and Face Protection
Food Safety PPE

Eye and face protection is essential when workers are exposed to flying particles, chemicals, or other hazards. Our Eye and Face Protection courses teach how to select, use, and maintain appropriate PPE to safeguard employees’ vision and facial safety.

8. Powered Industrial Trucks (1910.178)

Total Violations: 2,248
Most Cited Section: 1910.178(l)(1) – Employers must ensure the safe operation of powered industrial trucks.

Safety Made Simple Training Courses:
Forklift Safety
Rough Terrain Forklifts

Forklifts and powered industrial trucks are commonly used in material handling but can be dangerous if operators are not trained properly. Our Forklift Safety courses help ensure safe operation and compliance with OSHA standards.

9. Fall Protection – Training Requirements (1926.503)

Total Violations: 2,050
Most Cited Section: 1926.503(a)(1) – Employers must provide a training program for employees who might be exposed to fall hazards.

Safety Made Simple Training Courses:
Fall Arrest and Restraint Protection
Fall Protection Introduction to Fall Arrest and Restraint
Railcar Fall Protection Training
Fall Protection Working at Heights

Training is key to preventing falls. Our Fall Protection Training courses ensure that workers are fully equipped with the knowledge and skills to recognize fall hazards and use fall protection systems effectively.

10. Machine Guarding (1910.212)

Total Violations: 1,541
Most Cited Section: 1910.212(a)(1) – Machines must be properly guarded to protect operators and other employees from hazards.

Safety Made Simple Training Courses:
Machine Guarding

Machine guarding is essential to prevent injuries from rotating parts, ingoing nip points, and flying objects. Our Machine Guarding Safety course provides in-depth training on the importance of machine safeguards and how to implement them correctly.

The OSHA Top 10 list of cited violations underscores the ongoing challenges in workplace safety. By ensuring compliance with these standards and implementing thorough training programs, employers can significantly reduce workplace accidents and injuries. At Safety Made Simple, we provide online and in person training courses that cover these key areas and more, helping your team stay safe and compliant with OSHA regulations. Check out our courses today to ensure that your workplace remains a safe environment for everyone.

Hot Work – Don’t Play with Fire: Essential Safety Precautions

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In the grain handling industry, the phrase “hot work” can evoke a sense of anxiety among elevator managers, safety leaders, property insurers, and employees. Hot work, which includes activities like brazing, cutting, grinding, soldering, and welding, has been the cause of numerous fires and grain dust explosions. The heat generated from these activities can ignite combustible dust on surfaces and in suspension, resulting in smoldering fires, flash fires, and potentially catastrophic explosions. This post will explore the necessary precautions related to hot work, as required under OSHA Welding, Cutting, and Brazing Standard 1910.252 and OSHA Grain Handling Standard 1910.272.

Permit Authorization

OSHA’s Grain Handling Standard requires a hot work permit for all hot work performed within or near grain handling and storage areas. However, there are exceptions, such as when the employer or a representative is present during the hot work, or when the work takes place in welding shops or designated hot work areas outside the grain handling structures. Many companies opt to issue hot work permits for all work in or near grain handling areas as a best practice. It is essential to take a conservative approach to hot work in these environments.

A hot work permit includes details such as the work’s location, the nature of the task, and the name of the person performing the work. The permit requires the signature of an authorized person (e.g., a supervisor or fire safety officer), signifying that they have examined the area and confirmed all necessary precautions are in place before proceeding with the work.

Required Precautions

Hot work permits reflect the minimum safety precautions required under OSHA’s Welding, Cutting, and Brazing Standard 1910.252 (a) and are also referenced in the Grain Handling Standard. The precautions listed on the permit must be implemented before any hot work is allowed. These precautions are divided into several sections, including requirements for the area within 35 feet of hot work, equipment conditions, and fire watch considerations. Some of the common precautions include:

  • Ensuring that sprinklers and hose streams are operational.
  • Ensuring hot work equipment is in good condition (e.g., welding leads, torches).
  • Ensuring fire extinguishers, hoses, and other firefighting tools are operable.
  • Removing or covering combustible materials, including grain dust and oily deposits.
  • Ensuring that explosive atmospheres are eliminated.
  • Covering floors and walls with fire blankets or damp sand.
  • Protecting ducts, conveyors, bucket elevators, and other equipment that may carry sparks to distant combustible materials.

These precautions must be clearly marked on the permit, and the responsible person must confirm their implementation.

Fire Watch Requirements

OSHA’s standards for fire watch specify that fire watchers must be present whenever hot work is performed in locations where fires could develop. Specifically, a fire watch is required when:

  • Combustible materials are within 35 feet of the work area.
  • Combustible materials are more than 35 feet away but can easily be ignited by sparks.
  • There are floor or wall openings within 35 feet that could expose combustible material to sparks.
  • Combustible materials are adjacent to metal partitions, walls, or ceilings, where conduction or radiation could cause ignition.

Many companies go beyond the OSHA minimum and require a fire watch whenever hot work is conducted. Fire watch personnel must be trained in using fire-extinguishing equipment and know how to initiate evacuation procedures if necessary. OSHA mandates that fire watch be maintained during and for at least 30 minutes after the completion of the hot work to detect and extinguish potential smoldering fires. However, many grain handling facilities and insurance providers recommend extending the fire watch period to monitor for up to several hours after the work is completed, as grain dust can smolder for a long time after the visible heat has dissipated.

Hot work poses significant fire hazards in grain handling facilities. While OSHA standards set the minimum requirements, these guidelines should not be seen as a ceiling. Given the extreme risks associated with grain dust, it’s vital to adopt a conservative and proactive approach. Going above and beyond the minimum requirements is essential to protect employees, contractors, and the facility. Remember: don’t play with fire—take the necessary precautions, issue hot work permits, ensure proper fire watch, and continuously monitor for hazards.

Combustible Dust & Housekeeping in Grain Facilities

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Workers in grain elevators, milling, and processing facilities are well-acquainted with the hazards posed by combustible dust. These fine particles, when suspended in air, can lead to catastrophic explosions if not properly managed. Understanding the nature of combustible dust and implementing effective housekeeping practices are crucial steps in preventing such incidents.

Combustible dust explosion

Defining Combustible Dust

The National Fire Protection Association (NFPA) defines combustible dust as a “combustible particulate solid that presents a fire or deflagration hazard when suspended in air, or some other oxidizing medium, over a range of concentrations, regardless of particle size or shape.” Typically, these particles are 420 microns or smaller. In grain facilities, common combustible dusts include wheat, oats, soybeans, rice, hops (malted), barley, and various flours.

Components of Combustible Dust

Three key factors determine the combustibility of dust:

  1. Minimum Ignition Energy (MIE): The smallest amount of energy required to ignite a dust-air mixture. Materials with lower MIE values are more easily ignited.
  2. Minimum Explosive Concentration (MEC): The lowest concentration of dust in air that can support combustion. For grain dust, the MEC typically ranges from 50 to 150 grams per cubic meter.
  3. Deflagration Index (Kst Value): Indicates the potential severity of an explosion. Higher Kst values correspond to more violent explosions. For example, the Kst value for grain dust is approximately 89 bar-meters per second.

Housekeeping Practices to Prevent Dust Explosions

Effective housekeeping is essential in mitigating the risks associated with combustible dust. Key practices include:

  • Regular Cleaning: Implement routine cleaning schedules to remove dust accumulation from floors, equipment, and overhead structures.
  • Proper Ventilation: Ensure adequate ventilation to prevent dust from reaching explosive concentrations.
  • Equipment Maintenance: Regularly inspect and maintain equipment to prevent malfunctions that could generate sparks or heat.
  • Employee Training: Educate workers on the hazards of combustible dust and the importance of maintaining a clean environment.

OSHA Inspections

OSHA (Occupational Safety and Health Administration) requires mandatory inspections for grain handling facilities, but the specifics depend on the context. Here are some key points regarding OSHA’s requirements:

  1. General Duty Clause: OSHA’s General Duty Clause requires employers to provide a workplace free from recognized hazards. This means that employers in grain handling facilities must implement safety measures to protect workers from potential hazards, including those related to grain dust explosions.
  2. Standards for Grain Handling Facilities: OSHA has specific standards outlined in 29 CFR 1910.272, which covers grain handling operations. These standards include provisions for regular inspections and maintenance of equipment to prevent hazards such as grain dust accumulation, which can lead to explosions.
  3. Pre-Use Inspections: OSHA mandates that personal fall protection systems and other safety equipment must be inspected before use. While there isn’t a specific regulation mandating comprehensive facility-wide inspections, regular safety audits and inspections are considered best practices to ensure compliance with OSHA regulations.
  4. Recordkeeping: While OSHA does not require documentation of pre-use inspections, many employers choose to document inspections to demonstrate compliance and ensure that safety protocols are followed.
  5. Inspections by OSHA: OSHA conducts inspections of grain handling facilities to ensure compliance with safety standards. These inspections can be triggered by complaints, referrals, or as part of OSHA’s programmed inspection plans.

While OSHA does not mandate routine inspections of grain handling facilities in a prescriptive manner, it does require employers to adhere to safety standards that necessitate regular maintenance, inspections of equipment, and the implementation of effective safety practices to protect workers from hazards.

Recent Statistics on Grain Dust Explosions

Despite advancements in safety protocols, grain dust explosions continue to pose significant risks. According to Purdue University, there were nine grain dust explosions reported in the U.S. in 2023, resulting in 12 injuries but no fatalities. This reflects a slight decrease from the ten incidents reported in 2022. The ten-year average stands at 8.4 explosions annually.

Learn More

Understanding the properties of combustible dust, implementing stringent housekeeping practices, and always being prepared for an OSHA inspection are vital in explosion prevention plans. Learn more about being prepared in these SMS courses:

Grain Dust Explosion Prevention
Grain Dust Explosions: The Chain Reaction
Housekeeping & Combustible Dust

By adhering to safety standards and maintaining a clean environment, facilities can significantly reduce the risk of dust-related incidents, ensuring the safety and well-being of all personnel.

OSHA Inspections “The Playbook”

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If you are concerned about an inspection from the Occupational Safety and Health Administration (OSHA), there is good news.  OSHA Instruction CPL 02-01-004 is OSHA’s playbook when it comes to inspecting grain handling facilities.  This article will focus on several critical areas that will likely be included in the inspection process as well as “best practice” recommendations for compliance. 

Background

The standard for grain handling facilities, 29 CFR 1910.272 was promulgated on December 31st, 1987, and became effective March 30th, 1988.  Although the final rule applies to all grain handling facilities, it is not a true “vertical” standard since it is not intended to address all hazards found in these types of work environments. Therefore, be advised that other standards contained in 29 CFR Part 1910 for general industry and 29 CFR Part 1917 for marine terminals continue to apply to grain handling facilities.  29 CFR 1910.272, however, does take precedence inside grain handling facilities over other provisions in 29 CFR 1910 and 29 CFR 1917 for the specific hazards the grain standard addresses. 

Emergency Action Plans

29 CFR 1910.272 requires that an emergency action plan be in writing except for employers with 10 or less employees.  Employers with 10 or less employees will still have to comply with the 29 CFR 1910.38 (Emergency Action Plans) requirements and be able to substantiate that the plan is being communicated orally in an effective manner. All employees, including truck drivers, sales and office personnel, seasonal employees, and part-time employees must be included in determining the total number of employees at the workplace.  It is a recommended “best practice” that grain handlers develop a written emergency plan, regardless of the number of employees and train all employees routinely on the procedures within the plan. 

Training

In addition to the applicable training requirements outlined in 29 CFR 1910 General Industry, such as hazard communication, walking/working surfaces, lockout tagout etc., employees are required to be trained in the recognition and prevention of hazards associated with grain handling facilities, especially those hazards associated with their own work tasks.  Certified Health and Safety Officials (CSHOs) will verify that employees are trained in all aspects of their job tasks including bin entry and not to introduce ignition sources through the use of electric tools, welding, cutting, use of open flames or smoking in hazardous areas.  The standard does not require that training records be kept, however this is a recommended “best practice”.  The CSHO will substantiate training adequacy by reviewing the employer’s training records, if offered by the employee, or by interviewing a sample of employees.

Hot Work Permits

The standard does require that the employer issue a permit for hot work except where the employer’s representative, who would otherwise authorize the permit, is present while the hot work is being performed.  Welding shops authorized by the employer and hot work areas authorized by the employer outside of the grain handling structure are excluded from the requirements.  If a permit process is implemented, it must certify that the requirements contained in CFR 1910.252 Welding Cutting and Brazing are implemented and being followed.  If the employer elects to have a representative present instead of a permit, the employer must still follow the same requirements as if a permit were issued under CFR 1910.252.  It is a recommended “best practice” that a permit is issued each time hot work is performed in required areas.  While there is no requirement for permit retention, permits should be kept on file for a period of time that can demonstrate compliance with the standards.

Bin Entry Permits

A written bin entry permit is not required if the employer or representative who would otherwise be authorized to issue the entry permit, is present during the entire entry.  All other precautions contained within 1910.272 (g) must still be followed.  It is a recommended “best practice” that a permit process be implemented for entry into grain storage structures regardless of whether the employer or representative is present during the entire entry.  While there is not a requirement for permit retention, it is also recommended that permit documentation be kept on file for at least one year. 

The CSHO may also ask the employer to verify procedures to ensure that atmospheric testing equipment used to determine hazardous atmospheres including fumigants, oxygen deficiency, etc. are properly calibrated and maintained.  While there are no specific requirements within the standard for documenting calibration, it is a recommended “best practice” that calibration activities are documented.

Contractors

The standard requires the employer to provide specific instruction to contractors on the safety rules of the facility, including applicable provisions of the emergency action plan.  Simply providing a copy of the safety program would not ensure that the contractor has received sufficient information to take adequate precautions to prevent exposure to hazards.  It is a recommended “best practice” that employers meet with contractor employees prior to working at the facility to communicate and review safety requirements and potential hazards at the facility.  It is also a recommended “best practice” to document the subject matter discussed during the meeting, persons in attendance, hazards, and facility safety requirements discussed. 

Housekeeping

The standard requires that the employer develop and implement a written housekeeping program that establishes the frequency and methods determined to best reduce accumulations of fugitive grain dust on ledges, floors, equipment, and other exposed surfaces.  The program must also address fugitive dust accumulations in priority areas. The use of compressed air to blow dust from ledges, walls, and other areas shall only be permitted when all machinery that presents an ignition source in the area is shut down, and all other known potential ignition sources in the area are removed or controlled.  While not required, the use of a compressed air cleaning or blowdown permit is a recommended “best practice “to ensure and demonstrate compliance with the standard.

Preventive Maintenance

The standard requires regularly scheduled inspections of “at least” the mechanical and safety control equipment associated with dryers, grain stream processing equipment, dust collection equipment, and bucket elevators.  A certification record must be maintained for each inspection containing the date of inspection, name of the person who performed the inspection and the serial number, or other identifier of the equipment.  The standard does not require a specific frequency for preventive maintenance.   The CSHO will analyze the program based on the time period.  The program must be adequate for “peak” periods, such as harvest. 

This article outlined several of the critical requirements and best practices for maintaining compliance with OSHA 1910.272 Grain Handling.  Please remember that other general industry and maritime requirements contained in parts 1910 and 1917 will apply to grain handling facilities.  Please visit www.osha.gov for more information on OSHA’s playbook (CPL 02-01-004).

OSHA Compliance Inspections

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Our subject matter expert, Joe Mlynek, drafted this article for Grain Journal Magazine in the Summer of 2023.

A grain handling company recently asked me to perform a mock OSHA inspections at their facilities. The company had a policy and checklist for managing OSHA inspections but had never practiced or prepared in a simulated manner.

OSHA focuses their inspection resources on the most hazardous workplaces. There are six categories of inspections including:

1. Imminent danger situations which include hazards that could cause death or serious physical harm.

2. Severe Injuries and illnesses from workplaces that have reported a work-related fatality, inpatient hospitalization, amputation, or losses of an eye.

3. Worker complaints or allegations of hazards by employees.

4. Referrals from other federal, state, or local agencies, individuals, organizations, or the media.

5. Targeted Inspections of high hazard industries or individual workplaces that have experienced high rates of injuries or illnesses.

6. Follow-Up Inspections to verify abatement of violations cited during previous inspections.

For the purpose of the mock inspections, we simulated targeted inspections based on the local emphasis program (LEP) for grain handling facilities. LEP enforcement strategies are intended to address hazards or industries that pose a particular risk to workers.

Upon arriving at each facility, we discussed the importance of verifying the inspector’s credentials. During the opening conference I played the role of an OSHA compliance officer and indicated that the LEP targeted inspection would focus on the grain handling areas of the facility. I also requested the company provide documentation including OSHA 300 logs for the past five years, the written hazard communication program to include a safety data sheet for grain dust/whole grains, their lockout tagout program, a copy of their certification of hazard analysis for personal protective equipment, and items from OSHA instruction CPL 02-01-004 inspection of grain handling facilities. This directive instructs compliance officers to focus their attention on items including emergency action plans, training documentation, hot work permits, bin entry permits, provisions for contractors, the written housekeeping program, and preventive maintenance inspections.

Emergency action plans must be in writing except for employers with 10 or less employees. Employers with 10 or less employees will still have to comply with the 29 CFR 1910.38 (Emergency Action Plans) requirements and be able to substantiate that the plan is being communicated orally in an effective manner.

In addition to the applicable training requirements outlined in OSHA’s General Industry standards, OSHA 1910.272 also requires that employees be trained in the recognition and prevention of hazards associated with grain handling facilities, especially those hazards associated with their own work tasks. Employees must be trained in all aspects of their job tasks including bin entry and not to introduce ignition sources through the use of electric tools, welding, cutting, use of open flames, or smoking in hazardous areas. In addition, OSHA requires grain handling facilities to provide specific instruction to contractors on the safety rules of the facility, including applicable provisions of the emergency action plan.

OSHA 1910.272 also requires the employer to issue a permit for hot work except where the employer’s representative, who would otherwise authorize the permit, is present while the hot work is being performed. Welding shops authorized by the employer and hot work areas authorized by the employer outside of the grain handling structure are excluded from the requirements. If a permit process is implemented, it must certify that the requirements contained in CFR 1910.252 Welding Cutting and Brazing are implemented and followed. If the employer elects to have a representative present instead of a permit, the employer must still follow the same requirements as if a permit were issued under CFR 1910.252. 

Grain handling facilities must issue a permit for entering bins, silos, or tanks unless the employer or the employer’s representative (who would otherwise authorize the permit) is present during the entire operation. The permit must only be kept on file until completion of the entry operations.

OSHA 1910.272 requires that the employer develop and implement a written housekeeping program that establishes the frequency and methods determined to best reduce accumulations of fugitive grain dust on ledges, floors, equipment, and other exposed surfaces. The program must also address fugitive dust accumulations in priority areas.

The Grain Handling Standard requires regularly scheduled inspections of “at least” the mechanical and safety control equipment associated with dryers, grain stream processing equipment, dust collection equipment, and bucket elevators. A certification record must be maintained for each inspection containing the date of inspection, name of the person who performed the inspection and the serial number, or other identifier of the equipment.

Upon completion of the opening conference, I conducted a walk around inspection. The inspection focused on items including combustible dust housekeeping in priority areas, walking and working surfaces, hazard monitoring equipment required by the grain handling standard, machine guarding, and electrical hazards. The two company escorts were in my hip pocket the entire time. They kept detailed notes of everything I focused on and discussed during the inspection. They also took pictures of everything I took pictures of. They did a respectable job of not volunteering any information, while asking questions on items I commented on or wrote down. I could tell that they had been trained in their company’s inspection protocols.

Upon conclusion of the inspection, a closing conference was held. The management representatives did an impressive job of asking questions regarding potential violations. Noting the potential violations helps ensure that there will be no disputes at a later conference or hearing. It also allows the company time to address abatement of potential citations.

Consider performing random mock OSHA inspections at your grain handling facilities(s). Use the information covered in this article as a guide. I think you will find that they are a positive learning opportunity and good practice for the real thing. As they say, practice makes perfect, but only if you practice perfectly.

A Comprehensive Fall Protection Resource

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When working at heights, safety should always be the top priority. Using a Personal Fall Arrest System (PFAS) without evaluating fall clearance can lead to severe injuries or fatalities. Before utilizing a PFAS, workers must have a foundational understanding of fall clearance.

Calculating Fall Clearance

To accurately calculate fall clearance, you need to consider several crucial factors:

  1. The length of the connector, including the deceleration distance.
  2. The length of the worker’s body.
  3. An adequate safety factor.

We cover the formula for calculating fall clearance in this blog post. We’ll review here as well.

Deceleration distance refers to the vertical distance a worker travels from the moment the fall arrest system activates until they come to a complete stop. This distance is critical to ensuring that workers do not hit the ground or any obstacles below. Typically, the deceleration distance cannot exceed 42 inches (3.5 feet).

Example Calculation

Consider a six-foot worker using a body harness attached to a six-foot connector equipped with a deceleration device and a three foot safety factor. The connector is linked to the harness’s dorsal D-ring and a suitable anchorage point. Based on this scenario, the worker must ensure that the anchorage point is at least 18.5 feet above the lower level, any obstruction, or dangerous machinery. If there isn’t sufficient clearance, the worker should either select a different anchor point or utilize equipment such as aerial lifts or scaffolding. Opting for a shorter connector can also help reduce the required clearance distance.

Understanding Orthostatic Intolerance and Suspension Trauma

Most employees are aware of fall hazards in their work environment and possess knowledge of fall protection strategies, required equipment, and inspection protocols. However, they often lack an understanding of orthostatic intolerance and suspension trauma.

Orthostatic intolerance occurs when a worker experiences symptoms like light-headedness, heart palpitations, fatigue, and even fainting while standing upright. This condition arises from blood pooling in the leg veins due to a lack of movement or the force of gravity.

When a worker hangs in a harness, the straps can compress leg veins, significantly reducing blood flow to the heart. If not addressed, this can lead to loss of consciousness, a situation known as suspension trauma. Research indicates that prolonged suspension in a harness can result in unconsciousness and potentially death within 30 minutes.

Preventing Suspension Trauma

Workers can mitigate the onset of suspension trauma by actively pumping their legs while suspended, which helps facilitate blood flow back to the heart. Additionally, suspension trauma straps can be employed; these attach to the harness and allow workers to maintain an upright position, further aiding blood circulation.

The Importance of Quick Rescue

To prevent suspension trauma, rapid rescue of a suspended worker is critical. The Occupational Safety and Health Administration (OSHA) mandates that employers ensure the prompt rescue of employees in the event of a fall. This may involve an in-house rescue team or the deployment of first responders equipped with necessary tools like ladders, ropes, and aerial lifts.

Rescuers must be cautious when handling an unconscious worker due to the risk of reflow syndrome, which can occur when blood surges back to the heart after the harness is removed. To minimize this risk, rescuers should keep the worker’s upper body elevated at a 30–40-degree angle.

The Importance of Inspections

According to the Occupational Safety and Health Administration (OSHA) standards, it is essential for PFAS to be inspected before initial use and during each work shift. For general industry, OSHA 1910.140 states that “personal fall protection systems must be inspected…for mildew, wear, damage, and other deterioration, and defective components must be removed from service.” Similarly, for the construction industry, OSHA 1926.502 mandates that “personal fall arrest systems shall be inspected prior to each use for wear, damage and other deterioration, and defective components shall be removed from service.”

While OSHA does not require documentation of pre-use inspections, it’s wise for companies to document these inspections or incorporate them into daily hazard analysis processes. This ensures employees are aware of and comply with safety standards.

Annual inspections, required by ANSI standards, but considered voluntary are regarded as best practice. Document these inspections by having a competent person initial and date the equipment’s inspection tag or label. A more comprehensive option includes documenting the inspector’s name, date, equipment model and serial numbers, pass or fail grade, and any service or repair performed.

A common question regarding fall protection equipment, especially body harnesses and connectors, is about their service life. OSHA and ANSI do not specify a maximum service life for synthetic fiber products. However, both require that users remove equipment from service if it has been subjected to a fall. Many manufacturers provide an estimated or recommended service life, usually around five years, and many organizations follow this guideline.

Conclusion

Planning for fall-related emergencies is essential. Assess the activities that require fall protection equipment in your facility and ensure that a rescue plan is in place. Employees should be educated about the dangers associated with suspension trauma and never work alone when using fall arrest equipment. Remember, safety doesn’t have to be complex; simple steps, such as educating workers and adhering to inspection protocols, can prevent serious injuries and save lives.

Understanding Confined Space-Related Injuries and Fatalities

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Purdue University’s 2023 report on agricultural confined space-related injuries and fatalities reveals both alarming trends and areas of improvement within the industry. While there has been a notable decrease in the number of incidents compared to previous years, the statistics underscore the ongoing risks associated with confined spaces in agriculture.

Confined space entry report

Key Findings

  • Overall Cases: A total of 55 cases were documented in 2022, which includes 29 fatal and 26 non-fatal incidents. This represents a significant 33.7% decrease from the 83 cases recorded in 2021.
  • Grain Entrapments: The report documented 27 grain-related entrapments in 2022, showing a 35.7% decrease from the previous year. The remaining cases involved livestock waste handling, entanglements, and incidents related to grain dust explosions or fires.
  • Multiple Victims: Three incidents involved multiple victims, highlighting the potential for widespread danger in confined spaces.
  • Gender Representation: The report noted two female cases, including a dairy farm manure pit explosion and a fall from a grain elevator.
  • Geographic Distribution: Illinois reported the highest number of confined space-related cases (12), followed by Iowa (5). Historical data indicates that states like Iowa, Indiana, and Minnesota continue to account for a large percentage of grain entrapment cases.
  • Grain Dust Explosions: There were nine documented grain dust explosions at commercial facilities, resulting in 12 non-fatal injuries. Fortunately, no fatalities were reported in these incidents.
  • Aging Workforce: The average age of victims continues to rise, reflecting the increasing age of farmers in the U.S. In 2022, victims over 60 years old made up 28.6% of the cases where age was known.

Trends and Insights

Since the 1970s, Purdue University’s Agricultural and Biological Engineering Department has diligently documented incidents involving grain storage and handling facilities. This effort expanded in 2013 to include a broader range of agricultural confined space incidents, resulting in a comprehensive database (PACSID) containing 2,378 cases as of the end of 2022.

Despite the positive trend of fewer incidents, the report emphasizes the persistent need for effective safety training and proactive measures to protect workers. The methodology for collecting this data remains consistent, and while the numbers show improvement, the report acknowledges that many incidents, particularly non-fatal cases, may go unreported.

The Cost of Agricultural Confined Space-Related Incidents is Increasing

The economic implications of agricultural confined space incidents have changed significantly over time. In the past, the costs associated with fatalities or injuries were often manageable, covered by family, insurance policies, or local community support. However, with stricter OSHA regulations and increased scrutiny on workplace safety, non-exempt employers now face substantial financial risks. Jurisdictions have highlighted that neglecting employee safety can lead to hefty legal settlements, often reaching $10-17 million in cases involving fatalities or serious injuries, dwarfing OSHA fines that typically range from $50,000 to $100,000.

Valuable Resources for Safety Training

To aid in addressing these challenges, the website http://www.agconfinedspaces.org/ has been developed with support from a U.S. Department of Labor Susan Harwood Grant. This platform provides resources for safety training in agricultural confined spaces, focusing on grain storage and handling hazards. It includes:

  • Training materials and frequently asked questions.
  • Historical summaries of injuries and fatalities.
  • Educational resources aimed at young and beginning workers in the grain industry.

One highlighted program, “Against the Grain,” offers a comprehensive curriculum designed for youth and new employees at grain handling facilities. Since its launch, it has reached over 5,100 young individuals, demonstrating significant knowledge gains.

Additionally, training resources for emergency responders have been developed, with over 5,425 responders participating in these training sessions.

Conclusion

The findings from the 2023 report underscore the importance of focusing not only on reducing the number of incidents but also on strategically enhancing training for first responders. As the agricultural industry continues to evolve, so must our approaches to safety and emergency preparedness.

For a detailed look at the 2022 findings, methodology, and historical trends, please refer to the full report here.

Monotasking for Safety’s Sake

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During a recent safety inspection at a grain facility, one of our subject matter experts made it a point to engage with the facility manager and front line employees about their safety concerns. Typically, they expect to hear common issues like bin entry risks, worker fatigue, or the dangers of working on top of railcars. However, this time, the manager brought up an unexpected concern: multitasking.

This revelation was eye-opening. The manager expressed his discontent with employees splitting their attention between tasks, highlighting how it compromises their focus and safety. He emphasized the importance of assigning one task at a time, allowing employees to complete it fully before moving on to the next.

The Myth of Multitasking

The importance of monotasking

Multitasking is often viewed as a desirable skill in today’s fast-paced work environment. Many individuals might find themselves checking emails, texting, or taking calls while attempting to focus on their primary task. However, studies indicate that multitasking is not only ineffective but can also be dangerous.

The human brain is not wired to handle multiple tasks simultaneously. Instead of multitasking, individuals are merely switching their attention between tasks. This constant switching can lead to decreased accuracy, impaired judgment, and increased reaction times. According to a study by the University of California, distractions account for 32% of worker accidents, underscoring the dangers of divided attention.

The Impact of Distraction

The consequences of distraction can be severe. The National Highway Traffic Safety Administration reports that approximately 100 people die daily in vehicle crashes, with the risk of accidents increasing by 17% when drivers use their cell phones. While this scenario differs from working in a grain facility, the risks of distraction and its potential to cause accidents are similar.

Shifting to Monotasking

To mitigate the risks associated with multitasking, it is advisable to adopt a monotasking approach. This shift can enhance focus and reduce distractions, ultimately leading to a safer work environment. Here are some effective strategies to implement monotasking in the workplace:

  1. Prioritize Tasks: Begin by ranking tasks based on urgency and the focus required. Tackle the most critical and demanding tasks first thing in the day. Studies have shown that individuals who complete challenging tasks in the morning perform significantly better than those who do so later in the day.
  2. Structure Breaks: Incorporate structured breaks into the workday. Research indicates that taking regular 15-minute breaks can dramatically increase productivity. Employees should be encouraged to socialize during these breaks, avoid cell phone usage, and get outside for fresh air. This practice not only revitalizes employees but also enhances their focus and problem-solving skills.
  3. Educate Employees: Raise awareness among employees about the connection between distractions and workplace injuries. Emphasize the importance of monotasking and structured breaks to improve their focus and safety.

While eliminating multitasking may not always be feasible, fostering a work environment that promotes monotasking can lead to better productivity, higher quality work, and a safer atmosphere for all employees. Encouraging the team to focus on one task at a time can make a significant difference in their well-being and safety. Remember, sending employees home safely is the ultimate goal.

This blog drafted from an article by Joe Mlynek, published in July/August 2024 edition of Grain Journal Magazine.

Feedlot Safety Tips to Protect Workers and Livestock

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Agriculture is one of the most dangerous industries in the world, with high rates of occupational injuries, illnesses, and fatalities. The U.S. Bureau of Labor Statistics (BLS) consistently reports that agriculture has the highest rates of injuries of any major industry sector in the United States. In 2021, agriculture saw 19.5 fatal injuries per 100,000 full-time equivalent (FTE) workers. Specific subsectors, such as beef cattle production, face even greater risks. Nearly 45% of feedlot injuries involve handling cattle, making safety a top priority in feed yard operations. To create a safer environment for both workers and livestock, here is a viable list of feedlot safety tips. We’ve linked courses pertaining to each topic below. Please click the underlined text to learn more or test drive a full course.

Low-Stress Cattle Handling

Cattle handling is a leading cause of injuries in feedlots. Understanding cattle behavior and implementing low-stress handling techniques are critical. By respecting the flight zone (cattle’s personal space) and using predictable movements, handlers can reduce stress and prevent dangerous situations. Building trust with cattle is essential to minimizing risks.

Horses

Horses are involved in approximately half of all cowboy incidents. Since horses present a variety of safety challenges it is critical to have thorough horse selection criteria before they are deployed, and that they are trained for the specific situations where they will be used. The Brandon Wenta Tragedy, Cowboy Safety: Horses and Pen Conditions and Cowboy Safety: Cattle Movement are courses we offer on this subject.

Proper Equipment Maintenance & Use

Maintaining equipment like tractors, skid steers, and feed trucks is vital for preventing accidents. Regular inspections and prompt repairs ensure machinery operates safely, reducing the risk of malfunctions that could lead to injuries.

Slip, Trip, and Fall Prevention

Feedlots present various slip, trip, and fall hazards. Slick pen conditions are common year-round, and weather is always a factor. Proper footwear is essential. Preventing falls from heights such as bins and legs requires extensive training and use of special equipment. Remembering the three-point contact rule (two hands and a foot or two feet and a hand) reduces the probability of slips and falls when climbing ladders and when entering / exiting equipment.

Safe Operation of Mobile Equipment

Training workers on the safe operation of mobile equipment, such as feed trucks, loaders, UTVs (utility task vehicles), and ATVs (all-terrain vehicles) is crucial. Emphasize the importance of wearing seat belts and staying alert in areas where livestock or other workers are present. If you use ATVs consider replacing them with UTVs since they are inherently safer.   

Lockout/Tagout

Lockout/Tagout (LOTO) procedures are essential for preventing accidental equipment start-ups that could lead to serious injuries or fatalities. Ensure all workers are trained on LOTO protocols, which involve isolating and securing machinery before maintenance or repair work is performed. Proper LOTO practices are critical for protecting workers from unexpected releases of hazardous energy.

Fire and Explosion Safety

Fire safety is critical in feedlots due to the potential for fires and dust explosions. Establishing no smoking areas and using explosion proof fixtures and wiring are critical prevention measures. Ensure that fire extinguishers are well maintained, conduct fire/explosion drills and have all workers practice the fire evacuation plan. Hot work, such as welding, cutting, or grinding poses significant fire and explosion risks. Always follow proper hot work safety procedures, including obtaining permits and ensuring fire watches are in place.

Bin and Confined Space Entry Safety

Grain bins and confined spaces such as boot pits pose significant risks including engulfment, falls, and hazardous atmospheres. Workers should never enter these areas until an entry permit is completed and safety measures are followed. Always use appropriate harnesses and lifelines and ensure that all equipment is locked out and tagged out before entry. Ventilation should be tested to confirm it is safe before entry, and workers must be trained on the risks and proper safety procedures associated with bin and confined spaces and falls from heights. Our course, It Was A Good Friday: Grain Entrapment and Engulfment provides an impactful look at the importance of this issue.

Hydration and Heat Stress Prevention

Working in hot conditions can lead to heat stress and dehydration. Provide shaded rest areas, ensure easy access to water, and educate workers on the signs of heat-related illnesses and the importance of staying hydrated.

Emergency Preparedness

Every feedlot should have a clear, well-communicated emergency response plan. This includes procedures for handling medical emergencies, fires, severe weather, and other potential hazards. Regularly review and practice these plans with all employees to ensure everyone knows their role in an emergency.

Feedlot safety is multifaceted, requiring attention to a range of hazards from cattle handling to equipment maintenance and emergency preparedness. By implementing these safety tips, feed yards can significantly reduce the risk of injury and create a safer, more efficient working environment.

Remember, a commitment to safety is essential at all levels of the operation. Continuous training, vigilance, and proactive safety practices are the keys to protecting workers and livestock in this high-risk industry.

Remembering Rod: A Legacy of Safety and Change

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On November 3rd, 2006, our world shifted forever. This is the story of Safety Made Simple’s Anne Cook and Joe Mlynek’s friend and colleague, Rod, who tragically lost his life in a grain engulfment incident. It’s also the story of a company that underwent a profound transformation in its safety culture following that heartbreaking event.

The Incident: from Anne

That fateful Friday in Fall of 2006 began like any other. I was having lunch with Roger and Steve, who led our plant emergency organization. We were the plant radio monitors, accustomed to the usual chatter. But at 11:30 AM, everything changed. A frantic voice burst through the radio—our coworker Sean, urgently calling for help at Tank 2. Someone was buried in grain.

Time seemed to freeze. Roger and Steve sprinted to grab rescue equipment, leaving me alone to hear the escalating situation unfold over the radio. It was a surreal and terrifying moment. Then, the call came—it was Rod.

Rod wasn’t just a colleague. He was a respected grain operations supervisor with years of experience, my husband’s high school classmate, and our neighbor. The shock of losing someone so experienced and well-versed in safety was incomprehensible.

The Aftermath

As the emergency response unfolded, our office became the hub for family members, responders, and corporate leadership. The vivid snapshots of that day are etched in my memory—Rod’s wife, Jamie, coming into the office, the somber silence when she was informed, and the heartbreaking moment when she kissed Rod for the last time.

Rod’s passing was a watershed moment for our company’s safety culture. Despite our reputation as an industry leader, with robust safety systems and procedures in place, we realized that something fundamental needed to change.

The Reckoning: from Joe

Before the incident, we were proud of our safety achievements. We had reduced our incident rates by 50% and were recognized as industry leaders in safety management. However, Rod’s death was a harsh reminder that even the best systems could fail. We had focused on compliance, conditions, and non-serious injuries, believing that this would prevent severe accidents. We were wrong.

Mike Tyson once said, “Everyone has a plan until they get punched in the face.” Rod’s death was our punch, forcing us to reevaluate everything. We asked ourselves how we missed the warning signs and why we didn’t ask the right questions. Our CEO tasked us with ensuring such a tragedy would never happen again.

The Shift

We launched the Safety Improvement Initiative, bringing together representatives from across the company, external consultants, and our safety department. We sought a new path forward, guided by experts like Luis Sanchez from Behavioral Science Technologies. Luis taught us to focus on exposure, behavior, and engagement rather than just conditions.

We began by surveying our employees to understand our cultural landscape. We discovered that while employees believed we cared about their safety, safety was sometimes overshadowed by production demands. Our facilities worked in silos, lacking communication and collaboration.

The Transformation

We shifted our focus from non-serious injuries to preventing serious injuries and fatalities. We moved from a culture of compliance to one of genuine concern for our employees. We prioritized exposure over conditions, recognizing that people often get hurt by actions that intersect with hazards.

Leading with safety became a core principle. We asked ourselves three crucial questions before making decisions:

  1. How does my decision affect the safety of others?
  2. What is the impact on exposure?
  3. What is the effect on our culture?

We implemented job safety analysis, engaged employees in safety conversations, and fostered collaboration. We trained over 300 facilitators to identify and mitigate risks. We focused on feedback, using the CAR feedback method (Context, Action, Result) to provide specific and actionable guidance.

The Path Forward

Our journey didn’t stop with internal changes. We embraced near-miss reporting, sharing valuable insights across facilities to break down silos. We established accountability at all levels, incorporating safety into job descriptions and performance evaluations.

We recognized that serious injuries and fatalities often occurred during routine tasks, not just non-routine work. This insight shifted our focus to high-risk, frequent activities, ensuring our efforts aligned with actual dangers.

While implementing strategies like Hop (Human and Organizational Performance) may be complex, the essence is clear: focus on the working interface, engage employees, and lead with safety.

Rod’s memory lives on as a constant reminder of our mission. His story transformed our safety culture and reinforced our commitment to preventing similar tragedies. Safety is not just a policy; it’s a responsibility we carry with us every day.

As we move forward, let Rod’s legacy inspire us to lead with safety, embrace change, and ensure that no one else loses their life to preventable incidents. Our commitment to safety is a tribute to Rod, a testament to our growth, and a promise to protect every member of our team.

To learn more about grain engulfment training visit the complete Safety Made Simple catalog in the menu. To see the complete presentation from Convey 24, click this link for an audio only version, click here.

Environmental Risks in Confined Spaces

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In the realm of agricultural safety, understanding environmental risks in confined spaces is crucial. These hazardous environments present unique risks that demand awareness and proper safety protocols.

Why Focus on Agricultural Confined Spaces?

Agricultural confined spaces are essential for storing and handling crops. They pose serious risks to those who work in and around them. From engulfment hazards to toxic gases, these environments require careful management and adherence to safety guidelines.

Joe Mlynek, a partner at Safety Made Simple, presented for the National Grain and Feed Association (NGFA) webinar series on June 18th, 2024. He discusses the hazardous environmental risks associated with agricultural confined spaces in this video link. His insights are invaluable for anyone involved in agricultural operations or safety management.

Resources

For more educational resources on grain safety and agricultural confined spaces, visit the National Grain and Feed Association‘s safety page at ngfa.org/safety. Safety Made Simple subscribers can register for the hazardous atmospheres in confined spaces course by clicking here. This session focuses on atmospheric hazards in confined spaces. By the end of this course, participants will be able to recognize the effects of oxygen deficiency on the body, identify common atmospheric hazards and their health effects, and apply safe practices for atmospheric testing and ventilation in confined spaces.

Together, with the NGFA, we prioritize safety in agricultural operations. Stay informed about the latest safety practices and resources to protect yourself and your team. Together, we can mitigate risks and create a safer working environment.

Summer Safety at Maritime Facilities

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As summer heats up, so does the need for heightened safety awareness in maritime facilities like shipping and barge loading terminals. While the water may look inviting, it poses unique risks to workers, making it essential to have proper protocols and equipment in place to ensure their safety. Here’s what every working professional in maritime settings should know to stay safe this summer:

Personal Flotation Devices (PFDs)

Personal flotation devices, such as life preservers, life jackets, or work vests, are indispensable for workers exposed to the risk of falling into the water. These PFDs must meet U.S. Coast Guard (USCG) standards, be well-maintained, and promptly replaced if any defects are identified. Proper fit and fastening are vital to ensure they remain secure and effective.

Visibility and Rescue Equipment

Enhanced visibility is crucial, especially in low-light conditions. Ensure that life jackets feature reflective material for better visibility. Additionally, well-marked life rings and lines along the dock, equipped with USCG-approved specifications, are essential for swift rescue operations. Basket stretchers, blankets, and other coverings for rescued individuals should also be readily available.

Emergency Access and Guarding

In the event of an emergency, access to fixed and portable ladders must be clear, well-marked, and maintained in good condition. Rescue ladders should extend sufficiently both above and below the water surface to facilitate safe retrieval. Furthermore, areas where workers are at risk of falling into the water should be appropriately guarded to prevent accidents.

For comprehensive guidelines on maritime safety, please refer to OSHA’s 29 CFR 1917 Marine Terminals. By adhering to these protocols and ensuring the availability of necessary equipment, employers and workers alike can mitigate risks and promote a safer working environment in maritime settings.

In the dynamic and challenging world of maritime work, prioritizing safety is not just a legal requirement but a moral obligation. By investing in proper training, equipment, and protocols, we can protect the lives and well-being of those who keep our waterway industries afloat, ensuring safety at maritime facilities.

Beat the Heat: Tips for Staying Safe This Summer

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As the temperature rises, so does the risk of heat-related illnesses. Whether you’re working outdoors or simply going about your daily work routine, it’s crucial to take precautions to protect yourself from summer weather conditions. Here are some tips for staying safe this summer.

Hydration: Quench Your Thirst, Protect Your Health

One of the most important steps you can take to prevent heat-related illnesses is to stay hydrated. When the mercury climbs, your body loses fluids through sweat, increasing the risk of dehydration. This can lead to serious conditions such as heat stroke or heat exhaustion.

The symptoms associated with heat stroke include confusion, loss of consciousness, and seizures. The symptoms associated with heat exhaustion include headache, nausea, dizziness, weakness, irritability, confusion, thirst, and heavy sweating. Immediately seek medical attention if you or your coworker experience these symptoms.

To stay properly hydrated, and avoid heat stroke or exhaustion, make sure to drink plenty of fluids throughout the day, especially if you’re engaging in physical activity. Water is always a good choice, but for longer periods of exertion (two hours or more), replenish with electrolytes from sports drinks, electrolyte-infused water, or coconut water. Remember to drink at least one cup (8 ounces) of water every 20 minutes while working in the heat to keep your body cool and hydrated.

Rest: Take a Break, Beat the Heat

In addition to staying hydrated, it’s important to give your body the rest it needs to recover from the heat. As temperatures soar, so should the frequency and duration of your breaks. Listen to your body and take breaks as needed, even if you’re tempted to push through the heat.

The length of your breaks will depend on various factors, including the environmental heat, your level of physical activity, and any personal risk factors you may have. Whenever possible, seek out a cooler location to rest, whether it’s in the shade outdoors, an air-conditioned vehicle or building, or an area with fans and misting devices.

Remember, skipping breaks in hot conditions is not safe, so prioritize your well-being and take time to rest as heat stress rises.

Shade: Find Shelter from the Sun

When working outdoors, seek shelter in shady areas to protect yourself from the sun’s harmful rays. Whether it’s under a tree, in a tent, or near a building, finding shade can provide much-needed relief from the heat. If you’re indoors, make sure to rest in a cool area away from heat sources such as ovens, boilers, or furnaces.

By following these tips for staying safe this summer, you can help reduce the risk of heat-related illnesses and stay safe while being productive during the summer months. Remember, water, rest, and shade are your best allies in the battle against the heat stress. Stay hydrated, take breaks as needed, and seek shelter from the sun to beat the heat and stay healthy all summer long.

Essential Safety Inspection Checklist for Grain Facility Managers

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Safety inspections are a fundamental part of maintaining a secure and efficient grain facility. As a safety manager, your role in leading these inspections is crucial for identifying, eliminating, and controlling workplace hazards. Essential Safety Inspection Checklist for Grain Facility Managers outlines an essential checklist and best practices to enhance your safety protocols.

Effective safety inspections start with the right team. Include diverse roles in your inspection team, such as management and operational staff, and consider rotating team members to incorporate fresh perspectives and extend educational benefits across your facility. This variety not only improves hazard identification but also fosters a culture of safety among all employees. Consider this role as a part of your Safety Made Simple training journey and implement the courses accordingly.

Safety Inspection Checklist:

1. Operation Housekeeping:

  • Ensure that all walkways and work areas are free of grain dust and debris to prevent slips, trips, and falls.
  • Keep emergency exits and routes clearly marked and unobstructed to ensure a safe evacuation in case of emergencies.
  • Properly store and label hazardous chemicals to avoid health risks and chemical accidents.
  • Maintain electrical panels and energy isolating devices to be easily accessible and free of obstructions, enhancing response times during emergencies.
  • Regularly assess the overall cleanliness and organization of the facility to promote a safe and productive work environment.
  • Eliminate and control combustible dust in priority housekeeping areas.

2. Fire Protection and Security:

  • Secure all fixed ladders during non-operational hours to prevent unauthorized access and potential accidents.
  • Regularly inspect perimeter fences and facility gates for integrity and functionality.
  • Ensure that all security systems, including surveillance cameras, are operational, which helps in monitoring and controlling access to sensitive areas.
  • Enforce strict adherence to visitor protocols and hot work permit procedures to maintain control over facility access and high-risk activities.
  • Conduct monthly inspections and annual certifications of fire extinguishers to guarantee readiness in case of a fire.

3. Facility Safety:

  • Inspect and maintain guarding on all mechanical moving parts, such as augers, conveyor tail pulleys, V-belt drives, and rotating shafts,to prevent entanglement and other machinery-related injuries.
  • Label and check the functionality of all energy isolating devices to facilitate quick and effective responses in shutting down equipment during an emergency and effective lockout tagout activities.
  • Regularly check that all electrical enclosures are securely closed and that intrinsically safe equipment is used in  Class II hazardous locaitons.
  • Verify the condition and safety compliance of all tools and equipment, including portable ladders and fall protection gear, to ensure they are free from damage and functional.

4. Employee Behaviors:

  • Monitor adherence to isolation and lock-out/tag-out procedures to prevent accidental equipment startups.
  • Ensure that all personnel consistently wear appropriate personal protective equipment (PPE) and follow safe lifting practices to minimize the risk of injury.
  • Promote the use of correct tools for specific tasks and check that these tools are in good working condition.
  • Ensure that employees adhere to confined space entry and bin-entry procedures.

Routine safety inspections are vital for preventing accidents and ensuring the smooth operation of grain elevators and facilities. By following this Essential Safety Inspection Checklist for Grain Facility Managers and involving a diverse team in your safety protocols, you can significantly enhance workplace safety and operational efficiency. Remember, a proactive approach to safety can lead to a healthier work environment and more productive operations.