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Grain Dryer Safety: Preventing Fires and Protecting Workers

Posted on by Robin Walters

Grain dryers play a critical role during harvest, helping elevators manage moisture and maintain grain quality. But with high heat, fine dust, and heavy workloads, dryers also present serious safety risks. Fires, equipment failures, and even explosions can occur when maintenance and housekeeping take a back seat to production.

Safety Made Simple’s Joe Mlynek, a leading voice in agricultural safety, emphasizes that dryer safety starts long before the first load of grain hits the system. “Many dryer fires and near misses happen because of a lack of operator training, inadequate maintenance, and failure to follow operating procedures,” Mlynek notes. “Establishing a clear preventive maintenance and cleaning program is one of the simplest ways to avoid catastrophic incidents.”

Maintenance and Clean-Out: The Foundation of Safety

Preventive maintenance isn’t just about equipment longevity, it’s a frontline defense against dryer fires. Dust, fines, and chaff buildup around burners and screens can ignite under high heat, especially when airflow is restricted.

Operators should follow the manufacturer’s preventive maintenance schedule and complete inspections before, during, and after the drying season. Routine clean-outs of screens, ducts, fans, and collection systems are essential. Every facility should also have a dryer-specific maintenance checklist, ensuring critical areas are inspected daily.

Safety Made Simple’s Grain Dryers: Maintenance course provides practical guidance for operators on daily inspections, system cleaning, and maintenance routines to keep dryers running efficiently and safely throughout harvest.

Managing Product and Dryer Settings

A well-maintained dryer can still become a hazard if product settings aren’t properly managed. Grain should be dried at the correct airflow and temperature rates for each crop type and moisture level. Running dryers too hot to “speed up” throughput can lead to grain scorching, residue buildup, and worse, a fire.

Operators should monitor grain condition, exhaust air temperature, and dryer output frequently to ensure consistent, safe operation. Maintaining appropriate grain flow and avoiding overloading also help prevent heat concentration and uneven airflow.

Fire Prevention and Emergency Response

Fire prevention begins with awareness. Most dryer fires start small, inside a plenum, duct, or grain column but spread rapidly when air continues feeding the fire.

An emergency response plan specific to dryer fires should be included in every facility’s Emergency Action Plan. All operators should know how to:

  • Shut down equipment safely using emergency-stop procedures.
  • Isolate fuel and power sources to prevent gas from feeding a fire.
  • Avoid using fans to cool a burning dryer, which can intensify the flames.
  • Coordinate immediately with the fire department, ensuring they are familiar with the facility layout and dryer systems before an emergency occurs.

Safety Made Simple’s Preventing Grain Dryer Fires course reinforces these critical procedures, helping employees understand ignition sources, maintain equipment, and act quickly to contain fires before they spread.

Inspect. Train. Communicate.

Dryer safety requires continuous attention. Facilities should ensure:

  • Operators are trained annually and retrained whenever new equipment or procedures are introduced.
  • Housekeeping is maintained throughout harvest, keeping dust and debris clear of burners, sensors, and mechanical areas.
  • Emergency shutoffs, alarms, and sensors are tested regularly to confirm functionality.
  • Communication plans are in place so every team member knows their role during an emergency.

A Proactive Approach to Grain Dryer Safety

Preventing dryer fires and the injuries, downtime, and losses they cause comes down to preparation, training, and vigilance. With proper maintenance, consistent cleaning, and a clear emergency response plan, facilities can dramatically reduce risk and improve efficiency.

Safety doesn’t have to be difficult. Simple steps, like establishing a cleaning schedule and following manufacturer guidance, can prevent dryer fires and save lives.

Learn more by exploring Safety Made Simple’s full library of grain handling safety courses, including:

Because every safe season starts with a plan.

Protecting Your Team Around Grain Storage Piles

Posted on by Robin Walters

Working around temporary and permanent grain storage piles comes with a unique set of hazards that can put employees at serious risk. From struck-by incidents involving moving vehicles to caught-in hazards with conveyors and rotating machinery, the potential for injury is real, but many of these risks can be mitigated with proper planning and safety practices.

Struck-By and Backover Hazards

One of the most common hazards around grain piles is being struck by moving vehicles such as semi-trucks, payloaders, and skid steer loaders. Backover incidents can occur when employees are standing, walking, or kneeling near equipment in motion. To prevent these incidents, facilities should implement internal traffic control plans that clearly coordinate vehicle and pedestrian movement. Mark vehicle routes and pedestrian crossings, post traffic flow maps, and establish safe speed limits throughout the site.

During pile construction or reclaim operations, it’s important to create vehicle work zones. These zones can be defined using signage, caution tape, traffic cones, or other visual indicators. Employees should never enter a work zone without first communicating with the equipment operator, who should bring the machine to a safe stop before the worker enters. High-visibility clothing, maintaining safe distances, and staying in the operator’s line of sight are critical for safety.

Caught-In Hazards

Caught-in incidents occur when employees are exposed to moving machinery, such as stackers, portable conveyors, transport conveyors, gravity take-ups, V-belt drives, and tail pulleys. These hazards can result in severe injuries, including amputations or fatalities. To prevent caught-in accidents:

  • Enclose horizontal shafting less than 7 feet from the walking surface.
  • Encapsulate V-belt drives on all sides.
  • Guard gravity take-ups on all open sides.
  • Ensure tail pulleys and aeration fan blades are properly guarded.

Electrical and Trip Hazards

Cables and cords often run across walking and working surfaces in harsh environments. Damaged insulation or improperly protected cords can lead to electrical shock, trips, and falls. Using dropover guards or channel protector guards keeps cables organized, protected, and visible, allowing both vehicles and pedestrians to safely cross.

Grain Storage Pile Safety Training

Simple steps such as establishing vehicle work zones, creating traffic control plans, and guarding machinery, cords, and cables can significantly reduce the risk of injury. For teams working around grain piles, Safety Made Simple’s Grain Storage Pile Safety course provides the knowledge and tools needed to protect employees and coworkers. After completion, participants will be able to recognize common hazards, understand the importance of vehicle work zones, and apply safe practices that prevent injuries. For an additional resource, check out NGFA’s Safety Tip on Grain Storage Piles.

Investing in training helps ensure that every employee goes home safely at the end of the day because safety doesn’t have to be difficult, it just needs to be done correctly. Learn more about the our harvest safety courses and equip your team with the skills to work safely around grain storage piles.

Safety Practices to Prioritize During the Busy Season

Posted on by Robin Walters

Harvest season is the busiest time of year for commercial grain elevators. With long hours, heavy traffic, and constant movement of grain, it’s easy for safety to take a back seat but that’s exactly when it matters most. At Safety Made Simple, we know that staying proactive can prevent serious injuries and keep operations running smoothly, even when the pace is relentless. Here are a few safety practices to live by during the heat of harvest:

1. Manage Fatigue Before It Manages You

During harvest, extended shifts and early mornings are the norm. Fatigue isn’t just uncomfortable—it’s dangerous. Tired employees are more likely to make mistakes, miss hazards, and respond slowly in emergencies. Encourage frequent breaks, rotate responsibilities when possible, and monitor team members for signs of fatigue. Even a short rest can make a significant difference in alertness and reaction time. Here’s a course on preventing worker fatigue if you need a resource:

Preventing Worker Fatigue

2. Control Traffic and Equipment Zones

Grain elevators are busy places during harvest: trucks, front-end loaders, and forklifts are constantly on the move. . Establishing clear vehicle work zones and traffic patterns is critical. , Make sure to train employees to communicate before entering these spaces. Consistent traffic control plans prevent struck by and back-over incidents, and close calls. Here’s a course on moving vehicle safety:

Moving Vehicle Safety

3. Maintain Proper Grain Handling Practices

With more grain moving through the facility than at any other time of year, attention to proper grain handling and quality is essential. Follow established procedures for loading and unloading, maintaining grain quality, and ensure that any grain management systems are functioning correctly. Monitoring temperature, moisture, and CO₂ levels can prevent spoilage and reduce the risk of in-bin hazards. If you do need to enter a bin, be sure to adhere to the OSHA grain handling standards for pre-entry and entry. Review the standards here:

Safe Entry: Grain Storage Structures

4. Emphasize Housekeeping and Dust Control

Dust can accumulate quickly during harvest, creating slip hazards and the potential for fires and dust explosions. Regularly clean floors, platforms, and equipment areas, and inspect for dust buildup in hard to reach areas. Housekeeping isn’t just about appearance—it’s about preventing injuries and reducing the risk of fires or explosions. Here is a course on housekeeping and combustible dust best practices:

Housekeeping & Combustible Dust

5. Keep Communication Lines Open

Clear communication is the backbone of a safe harvest. From radio checks between spotters and equipment operators to daily safety briefings, everyone should know their role and the risks present each day. Ensure that all team members are trained on emergency procedures, know where first aid equipment is located, and understand reporting protocols for near misses or unsafe conditions. Deploying an effective communication only works with active listening! Review this course on effective communication and active listening:

Effective Communication & Active Listening

6. Review Emergency Preparedness

Harvest season is unpredictable. Equipment malfunctions, engulfment, and vehicle accidents can happen. Having emergency plans in place—and making sure employees know them—can mean the difference between a minor incident and a serious injury. Conduct quick refreshers on confined space procedures, first aid, and fire response, and confirm that safety equipment is accessible and operational.

Confined Space Entry: The Basics
First Aid Basics
Portable Fire Extinguishers
Exit Routes & Emergency Responses

7. Train, Retrain, and Reinforce

Even experienced employees benefit from reminders and refreshers. Safety Made Simple offers a range of courses designed for grain elevator teams, from Grain Handling Safety to Housekeeping & Combustible Dust and Equipment Operation. Prioritizing training during the harvest season keeps safety front-of-mind when the operation is busiest.

Customize a Learning Path
Grain Harvest Safety

Focus on safety

Harvest season is challenging, but safety doesn’t have to take a back seat. By managing fatigue, controlling traffic, maintaining grain handling standards, emphasizing housekeeping, fostering communication, and reviewing emergency procedures, your team can work efficiently and safely. Visit our course catalog and our library of resources that help your grain elevator stay safe during the busiest season of the year. Need help, please reach out!

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Harvest Readiness: Keep Your Facility Safe and Efficient

Posted on by Robin Walters

Harvest season is one of the most demanding times for grain handling facilities. It’s a period where multiple risk factors converge, creating what safety professionals often call a “perfect storm.” Seasonal workers, long hours, high-volume operations, dust accumulation, dryer operations, vehicle traffic, and extreme weather all combine to make safety and preparedness critical. Taking proactive steps now for harvest readiness can prevent injuries, equipment damage, and even catastrophic events like fires or dust explosions.

Grain Safety Starts with Your Team

During harvest, many facilities rely on seasonal workers to meet operational demands. These workers must receive thorough training on facility-specific hazards and safe work procedures. Training should cover topics like:

For tasks involving bin entry, working at heights, or preventive maintenance, additional training is essential. Clearly defining the scope of each worker’s responsibilities and providing proper instruction reduces the likelihood of accidents.

Personal Protective Equipment (PPE)

Ensure sufficient PPE is available for all employees, including head protection, filtering facepiece respirators, eye protection, gloves, and high-visibility clothing. Supervisors should routinely review PPE requirements and monitor proper usage throughout harvest. Safety Made Simple learners can complete the following courses for the season:

Dust Management and Explosion Prevention

Grain dust is one of the most significant hazards in any facility. Dust accumulation, combined with confined spaces and ignition sources, can lead to explosions. Effective housekeeping is essential:

  • Conduct regular inspections and cleaning of priority areas.
  • Avoid using compressed air to clean dust, as it suspends particles in the air and increases risk.
  • Implement dust collection and ventilation systems wherever feasible.

Following these practices helps maintain a safer work environment and reduces the risk of combustible dust incidents. Courses available for Safety Made Simple learners include:

Dryer Maintenance: Preventing Fires

Grain dryers are critical for post-harvest operations but can pose unique hazards. Dryer fires often result from operator error, inadequate cleaning, or improper maintenance. Preventive measures include:

  • Following manufacturer-recommended maintenance schedules before, during, and after harvest.
  • Regularly cleaning dryer screens and inspecting emergency shutoff controls.
  • Ensuring operators are trained in the safe operation of dryers.

In the event of a dryer fire, your facility must have a documented emergency response plan:

  • Notify the local fire department immediately.
  • Isolate equipment using emergency stops, lockout/tagout procedures, and shutoffs.
  • Identify the location of the fire and, if safe, use proper PPE to manage small incidents.
  • Conduct a fire watch afterward to monitor for lingering hot spots.

Safety Made Simple offers a few preventative courses on grain dryers, they include Grain Dryers: Maintenance and Preventing Grain Dryer Fires.

Additional Safety Considerations

Harvest demands long hours, which can lead to worker fatigue. Symptoms like forgetfulness, reduced vigilance, irritability, and slower reaction times increase risk. Combat fatigue by ensuring routine breaks, proper hydration, and communication throughout shifts. Our Grain Harvest Safety course is a great refresher or introductory course for new team members.

Vehicle traffic during harvest is another critical concern. Establish clearly marked traffic routes, use high-visibility signage, and require employees to confirm vehicle movements before crossing. Courses available for vehicle safety are appropriate year-round, but especially a good reminder at harvest:

Lead with Safety

Management and supervisors set the tone for facility safety. Leading by example, reinforcing routine safety practices, and integrating safety discussions into daily communication establishes a culture where employees feel empowered to act safely.

Harvest may be the perfect storm, but with planning, training, and vigilance, facilities can navigate it safely. Prioritize grain safety, preventive maintenance, dust control, and emergency preparedness. Simple steps taken before and during harvest—such as regular cleaning, proper PPE use, and maintenance schedules—can prevent injuries, protect property, and keep operations running smoothly. Our purpose is simple: to provide a clear message that shows people the safe way home.

Emergency Response Starts Today

Posted on by Robin Walters

Industry experts share lessons and why proactive preparation trumps reactive response every time in an emergency situation.

The high-risk environment of grain handling and processing can create a perfect storm of life-threatening emergency situations that every company and employee should be aware of. The panel of industry safety experts at this year’s CONVEY Conference, held in Omaha, Nebraska, took it a step further.

The environment employees work in everyday can create  life-threatening situations they should be prepared for.

Co-hosted by GEAPS, the NGFA, and Grain Journal, the conference featured a packed three-day agenda focused on safety, compliance, and operational improvements.

The standout session, “Emergency Preparedness and Response” on July 15 took a deep dive into practical, proactive approaches for managing high-stakes incidents in grain facilities. The first-hand accounts by the panel’s industry experts framed the necessity and the strategies the safety team can use to ensure employees are prepared.

Emergency Response Panel

The panel included three safety industry staples:

Together, they laid out the scope of emergencies that can occur in grain facilities, backed by personal stories of dust explosions, fires, structural failures, entrapments, chemical releases, severe weather events, and workplace violence, the conversation and education was never dull.

“Emergency preparedness can’t be a checklist that sits on a shelf,” said Mlynek. “You have to look at what could happen at your location and think seriously about what equipment and services you’ll need in the critical hours that follow.”

Mlynek shared about a 2005 dust explosion that became a turning point in his career.

“It was a $36 million insurance claim.  No one was killed, thankfully, but the response revealed a litany of errors,” he said.

His takeaway? Comprehensive emergency planning and effective response relationships are essential, not optional.

Adding to the conversation, Roth emphasized the value of building emergency response relationships early. “We invite the fire department out annually. Having that working relationship before an incident occurs makes all the difference,” he said.

For facilities that struggle to engage local emergency services, the panel encouraged the audience to offer their site(s) as training opportunities for local emergency response teams. The collaboration, they agreed, serves as a great vehicle to build rapport, relationships and create familiarity for the professionals responding to the emergency call.

Clarity and Communication Save Lives

One key area of improvement the panel discussed was ensuring clear and consistent messaging throughout a facility.

Roth noted that even simple changes, like signs indicating severe weather meeting points, can have a major impact.

“When we asked new team members where they’d go during severe weather, that was the most frequently missed question. After we posted signs and included it in training videos, it rarely gets missed now.”

The conversation also turned to ensuring contractors and visitors are informed.  

“Documented emergency procedures for contractors aren’t just good practice—they’re a service to those workers,” Mlynek explained.

Planning Beyond the Obvious

When asked about overlooked yet critical resources, Mlynek recommended assembling an emergency resource list, a detailed inventory of specialized tools and services that may be needed after a major incident.

“You won’t think about needing infrared cameras, concrete cutting companies, or salvage crews…until you do,” he said. “It’s about being ready for the unexpected.”

More importantly, he reminded attendees that the industry often puts more effort into rescue training than prevention .

“As an industry, I wish we practiced safe entry into  grain bins as much we practice  rescuing people from them.  Both are equally important.”

Joe Mlynek, Safety Made Simple

Worst-Case Planning

Mlynek’s final challenge struck a chord with attendees: plan for the worst-case scenario.

“Always assume you have victims. Assume it’s nighttime. Assume it’s the hottest or coldest day of the year,  Assume you have no power and no water. The manager might be on vacation, and you may be dealing with this alone for several days. How will you respond?”

The Takeaways:

For safety professionals and facility managers, the message from the panel was clear:

  • Review and revise emergency response plans regularly
  • Foster relationships with local responders before an incident occurs
  • Ensure signs, training, and communication are effective and up to date
  • Include contractors and visitors in your safety protocols
  • Prepare for long-duration, high-impact incidents, not just routine emergencies

In the grain industry, emergencies are not a matter of if, but when.

There is no substitute for preparedness!

Build a Workplace Safety Business Case

Posted on by Robin Walters

When it comes to workplace safety, most of us know it’s the right thing to do but convincing decision-makers to invest in it can be a challenge. Why? Because safety can be viewed as an expense rather than a long-term investment.

Essential Safety Inspection Checklist for Grain Facility Managers

At Safety Made Simple, we believe safety is more than compliance—it’s a core business strategy that protects people and strengthens performance. If you’re tasked with justifying safety improvements, here’s how to build a compelling business case that speaks the language of leadership.

What Is a Business Case?

A business case is more than a presentation, it’s a strategic argument that outlines the why, how, and what behind an investment. Whether you’re proposing new equipment, safety software, or training programs, your business case should include:

  • A clear definition of the safety problem
  • Cost-benefit analysis and return on investment (ROI)
  • Implementation plan and budget
  • Time, resources, and maintenance requirements
  • Consequences of inaction
  • Comparison of alternative solutions

Overcome Common Barriers

Safety professionals often come from a place of doing what’s right. Leadership, on the other hand, may be focused on costs, ROI, and business performance. Bridging that gap requires preparation, collaboration, and a shift in perspective.

Understand your audience. Know how management views safety. Are they skeptical? Cost-focused? View it as non-critical? Anticipating concerns will help you frame your case around business impact.

Involve leadership early. Collaborating with a COO, CFO, or Director of Operations can help you identify potential barriers, align your messaging, and anticipate tough questions.

Timing Is Everything

Don’t wait until budget season is in full swing. Start building your case at least 120 days before the company’s fiscal planning cycle. This gives you time to collect data, build consensus, and strengthen your proposal.

Focus on What Decision Makers Value

To resonate with leadership, your business case should emphasize outcomes they prioritize, such as:

  • Return on investment (ROI)
  • Cost savings (both direct and indirect)
  • Improved organizational safety metrics (TRIR, LWR)
  • Reduced financial risk
  • Enhanced compliance and corporate reputation

Bonus: Use financial language like “percentage of payroll,” “cost per employee,” or “impact on production” to connect the dots.

Don’t Forget the Data

The stronger a company’s safety and health performance, the harder it is to justify additional investment. That’s where data makes the difference.

  • The average direct cost of a medically consulted workplace injury is $45,000
  • A single work-related fatality averages $1.4 million in direct costs
  • Indirect costs (productivity loss, insurance, turnover, legal fees) can be 2x or more than direct costs

To obtain more detailed information about the direct and indirect costs associated with an injury or fatality, visit our “Safety Pays” web page. These numbers paint a powerful picture, but if you need help calculating your own, try OSHA’s Safety Pays Tool calculator.

This free estimator shows:

  • Total injury costs based on incident type
  • How much revenue is needed to offset those costs
  • Comparisons to industry peers
  • Projected savings from injury prevention programs

According to OSHA and the American Society of Safety Professionals (ASSP), every $1 invested in safety returns $2–$6, and effective injury prevention programs can reduce injury rates by 15% to 35%.

Safety Is a Business Strategy

Yes, safety programs require investment, but so does every initiative that strengthens your business. A well-prepared business case shifts the narrative from compliance cost to strategic value.

By anticipating concerns, aligning with company goals, and using solid data, you can turn safety into something leadership not only supports—but champions.

Need help?
Safety Made Simple offers flexible, effective training solutions backed by real-world experience and measurable results. Let us help you build a safer, smarter workplace. Contact us to learn more about our online training solutions.

Preventing Heat Stress in the Workplace

Posted on by Robin Walters

As summer temperatures rise, so do the risks associated with heat stress in the workplace —especially in agriculture, grain handling, and other physically demanding industries. Heat illness can affect anyone working in high temperatures, particularly those exposed to direct sunlight or working in enclosed, poorly ventilated spaces like grain bins, warehouses, or equipment sheds.

Heat stress isn’t just uncomfortable, it can be deadly.

Why Heat Stress Matters

When a person is exposed to excessive heat, their body struggles to maintain a normal internal temperature. If the body cannot cool itself through sweating and hydration, this can lead to heat exhaustion or the more serious condition of heat stroke. These illnesses can develop rapidly, and without intervention, may result in permanent damage or even death.

Know the Warning Signs

Employees and supervisors should be able to recognize early symptoms of heat illness. These may include:

  • Headache or dizziness
  • Heavy sweating or confusion
  • Muscle cramps or nausea
  • Weakness or fainting
  • Hot, dry skin (a possible sign of heat stroke)

In high-heat environments, recognizing these signs early can save lives. And knowing what to do in an emergency—such as moving the person to a shaded area, providing cool water, and calling for medical help—is just as critical.

Prevention Starts with Education

At Safety Made Simple, we offer targeted training courses designed to prepare your team for working safely in hot environments:

Heat Safety: Avoid the Stress

This course explains what happens to the body during heat exposure, how to recognize symptoms in yourself and others, and how to prevent heat-related illness altogether. It’s a great resource for employees working outdoors or in unconditioned indoor spaces during the warmer months.

Heat Illness Prevention

This course takes a deeper dive into identifying dangerous symptoms, responding to emergencies, and implementing prevention strategies at both the employee and employer level. It provides practical steps to help reduce the risk of heat-related incidents in the workplace.

Protecting Workers is Everyone’s Responsibility

Employers can help by ensuring access to water, rest breaks, and shade or cooling stations. Training, like the kind offered by Safety Made Simple, adds another layer of protection. Empowering workers with the knowledge to look out for themselves and their coworkers is key!

Don’t wait for a heat-related incident to take action. Prepare your team before temperatures peak. Start your training today through a free course test drive or call our support team to get these courses added to your line up:

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 contacting us today. 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

Posted on by [email protected]

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 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.