Tag: combustible dust

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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Combustible Dust & Housekeeping in Grain Facilities

Posted on by [email protected]

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.