Best Practices and Products to Reduce Grain Bin Entry

Grain bins can range in size depending on the facility's needs and are used to store commodities or other products for later use. Nationally, there continues to be an increased number of fatal and non-fatal grain bin incidents compared to previous years.

Each year, inspect the bin to ensure it has been adequately maintained before storing grain or any product in a grain bin. Before filling the bin, check the roof and vents to ensure they are correctly sealed to reduce the risk of weather and moisture negatively affecting your commodity from spoilage. A final check visually looks for cracks or missing bolts on your grain bin panels or foundation. If cracks or missing bolts are present, make repairs before using the bin. Repairs and maintenance should be checked to avoid an increased chance of spoilage and decreased structural integrity of the bin.

Best Practices to Reduce Bin Entry

Utilizing best practices and easily installed products can significantly reduce the number of times a farmer or farm worker should need to enter a grain bin and decrease many of the unsafe factors related to working around grain and grain storage structures.

1. Harvest and store grain at the Recommended Moisture Level

Harvesting and storing grain at the correct moisture level helps reduce the risk of hot spots, clumping, or bridging. For bin storage, the recommended moisture levels for corn is 15% and 13% for soybeans. If the commodity is harvested at a high moisture level, the facility must have a plan to stop spoilage. Spoiled grain and fumigation may cause gases and contaminants to develop in a grain bin. In addition, ensure that all grain placed inside the grain bin is suitable for the projected storage time.

2. Grain Level Indicators

Grain level indicators cost approximately $150-$200 per unit and help producers monitor for spillage and ensure the proper filling height of a grain bin while remaining on the ground. This simple device includes a flap on the bin's interior wall and an indicator device on the bin's exterior wall to view the grain levels inside the bin. As shown in Figure 1, the grain level indicator uses the grain pressure pushing against the flap on the interior wall, which changes the exterior wall device to a distinct color to show the level inside the bin. Grain level indicators should be installed vertically with adequate spacing between each indicator. The amount of grain level indicators depends on the size of your grain bin.

3. Lockout/Tag Out

Grain entrapment and engulfment can occur in various situations, including the collapse of a grain bridge, avalanche of a grain wall, and by flowing grain or using a grain vacuum. One way to reduce the risk of grain entrapment is to practice proper lockout/tagout procedures for securing energy sources to ensure that the power source remains off if someone needs to be inside the bin. As shown in Figure 2, all energy sources have been shut down and completely secured before entry occurs. Every employee should be notified of the lockout/tag out before entry occurs, which alleviates the possibility of sumps or side draws being opened for use. As shown in Figure 3, lockout/tagout kits include multiple locks for each employee and a card that should be completed before attaching to the power supply. Each lock is given one key with no replication, so the employee who locks out the power supplies can only remove their lock. Lockout/tagout kits can be purchased for approximately $100-$150 from various local and online retailers specializing in industrial or agricultural safety. Kits are available with multiple fixtures that cover a broad range of breakers and plugs to secure equipment. When a situation occurs where multiple employees must be involved, each employee should place their lock on the suggested lockout device before entry.

4. Clump Busting Equipment and Sump Guard

Grain clumping occurs when a moisture imbalance is inside a grain bin and can reduce or stop grain flow, causing a potentially hazardous situation. Entrapment and engulfment can happen when employees enter the bin and try to break up clumped grain from inside. Commercial products that have shown effectiveness in assisting grain flow are available to reduce clumped grain. Power sources for these products may vary, such as a standard cordless drill or a hydraulic motor attached to a tractor, as shown in Figure 4. Regarding designs, some clump-busting products are placed directly over the sump of the grain bin, while others are connected to a permanent sweep within the bin that disconnects when the sweep is running.

4. Grain Bin Fall Protection System

If someone must climb up the grain bin, fall arrest systems can be installed at the tie-off point for the person climbing the ladder. Also, each employee should have a harness fitting their body type and weight for a fall protection system. A typical setup includes a set length of rope or cable that is the correct size for the bins at your operation. Paired with the rope or cable will be two steel snap hooks that should be connected to the bottom and top of the bin. An example of this setup is shown in Figure 5. The rope or cable would be positioned directly beside the ladder and extend multiple feet above the top entry door of the bin. This setup allows the person to remain attached to a safety line when entering a bin door. You can unhook and reposition your harness from the top of the bin roof to the safety line inside the bin. In 2018, the American Society of Agricultural and Biological Engineering (ASABE) S624 recommended anchor points be placed inside a bin. The bin manufacturer should be consulted to determine if anchor points can be installed in all pre-and post-2018 bins.

New grain bins being constructed may add stairs to replace the ladder for safer access to the bin roof and hatch. As shown in Figure 6, spiral staircases are both safer and ergonomically easier to climb than the standard grain bin ladder. As mentioned, anchor points within a grain bin are optional and not standard when building a grain bin. If installed by a grain bin manufacturer, anchor points would be placed at the roof's peak and a foot below your top entry. The anchor point below the top entry door is mounted to the top panel of the grain bin. Anchor points are vital when entering through the top hatch on a grain bin. Anchor points and lifeline harness systems help eliminate the possibility of engulfment or entrapment within a grain bin.

Conclusion

Reducing the number of grain bin entries and working with the bin manufacturer to install anchor points on a grain bin can decrease the number of injuries and fatalities. The first step is following best practices when harvesting and storing your commodity at the recommended moisture level. Out-of-condition grain is one of the main factors in entrapment and engulfment incidents. Commercially available products such as bin level indicators to monitor grain levels and clump-busting equipment to promote proper grain flow can decrease the need to enter the bin. If a person needs to enter a grain bin, the person should be equipped with a properly fitted harness and lifeline system attached to a manufacturer-installed anchor point. Before installing an anchor point to a grain bin, the farm owner or manager should consult the grain bin manufacturer to have them determine if their grain bin can safely accommodate an anchor point and lifeline system. Fall protection systems and spiral staircases on grain bins improve access and reduce the risk of slips, trips, and falls. Utilize lock out/tag out to properly shut down and secure power supplies. Make safety a top priority in your agricultural operation.

This work was supported by a grant from the Northeast Center for Occupational Health and Safety: Agriculture, Forestry, and Fishing (NIOSH grant #2U54OH007542).

Photo credits: Stephen Brown, Linda Fetzer, and Kasey Snell, Penn State Ag Safety and Health

Sources

Aerating grain in storage. (2024) University of Georgia Extension.

American Society of Agricultural and Biological Engineers. (2018) Grain bin access standards.

Bechman, T. (2021) 10-point checklist for grain bin safety.

A look at workplace safety in agriculture. (2020) Bureau of Labor Statistics, U.S. Department of Labor, The Economics Daily.

Cheng, Y., Nour, M., Field, B., Ambrose, K., & Sheldon, E. (2023). 2022 Summary of U.S. Agricultural Confined Space-Related Injuries and Fatalities.

Dorn, T. (2007). Clean and prepare bins before harvest to maintain grain quality, value. University of Nebraska-Lincoln, Institute of Agriculture and Natural Resources.

Duty to have fall protection and falling object protection. (2016) U.S Department of Labor - Occupational Safety and Health Administration.

Grain handling (n.d.) Occupational Safety and Health Administration.

Lockout/tagout: OSHA fact sheet (2022.) U.S Department of Labor - Occupational Safety and Health Administration.

On-farm grain bin inspection guidance for safe entry lifeline and anchor point retrofit. (2022) Penn State Extension.

Sadaka, S., Atungulu, G., and Olatunde, G. (2016) Safe grain storage period. University of Arkansas System.