Grain Handling Safety Manual

OSHA Grain Handling Facilities Standard

Federal OSHA maintains a specific Grain Handling Facilities standard, 29 CFR 1910.272.

The standard contains requirements for controlling grain-dust fires and explosions and certain other hazards associated with grain-handling facilities.

Depending on the provisions involved, the standard applies to operations including:

• Grain elevators.
• Feed mills.
• Flour mills.
• Rice mills.
• Dust pelletizing plants.
• Dry corn mills.
• Soybean flaking operations.
• Dry grinding operations of soycake.

Certain additional requirements apply specifically to grain elevators.

The Grain Handling Facilities standard applies in addition to other relevant occupational safety and health requirements.

A Grain Handling Safety Manual should therefore address both the requirements specifically applicable to grain handling and other safety programs necessary for the facility’s actual operations and employee exposures.

What Should a Grain Handling Safety Manual Include?

The contents of a Grain Handling Safety Manual should reflect the operations actually performed at the facility.

Depending on operations, the manual may address:

• Grain handling safety responsibilities.
• Emergency Action Plan.
• Employee training.
• Grain-bin and silo entry.
• Engulfment prevention.
• Grain entrapment.
• Hazardous atmospheres.
• Combustible grain dust.
• Dust control.
• Housekeeping.
• Hot Work.
• Lockout/Tagout.
• Preventive maintenance.
• Bucket elevators.
• Conveyors.
• Augers.
• Grain dryers.
• Grinding and milling equipment.
• Dust collection systems.
• Grain receiving.
• Truck and railcar unloading.
• Grain loading.
• Flat storage structures.
• Mobile equipment.
• Fall protection.
• Personal Protective Equipment.
• Respiratory hazards.
• Emergency rescue.

Programs should be selected according to the facility’s processes, equipment, grain products, storage structures, maintenance operations, and employee exposures.

Grain Handling Safety Program

An effective Grain Handling Safety Program establishes responsibilities and procedures for preventing grain engulfment, controlling combustible dust, maintaining equipment, preventing fires and explosions, controlling hazardous energy, and protecting employees during routine and non-routine operations.

Management should provide employees with appropriate equipment, PPE, training, supervision, maintenance resources, emergency procedures, and safe work practices.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate grain-handling hazards.
• Maintain applicable written safety programs.
• Control combustible grain dust.
• Establish grain-storage entry procedures.
• Maintain equipment.
• Control ignition sources.
• Establish Hot Work procedures.
• Coordinate contractors.
• Provide required PPE.
• Establish emergency procedures.
• Investigate workplace incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow established procedures, use required PPE, maintain good housekeeping, follow hazardous-energy controls, obtain required authorization before performing special tasks, and promptly report unsafe conditions, equipment defects, dust accumulations, fires, spills, and other hazards.

Grain Handling Hazard Assessments

Hazard assessments should consider:

• Grain receiving.
• Grain storage.
• Grain transfer.
• Conveying systems.
• Bucket elevators.
• Augers.
• Grain dryers.
• Milling and grinding.
• Dust collection.
• Maintenance.
• Grain-bin entry.
• Truck and rail operations.
• Mobile equipment.
• Employee access.

Potential hazards may include:

• Engulfment.
• Entrapment.
• Suffocation.
• Oxygen deficiency.
• Toxic atmospheres.
• Combustible dust.
• Fire.
• Explosion.
• Mechanical hazards.
• Hazardous energy.
• Falls.
• Struck-by hazards.
• Noise.
• Respiratory exposure.

Assessments should be reviewed when equipment, processes, grain products, or facility conditions change.

Job Safety Analysis (JSA/JHA)

A JSA/JHA may be used to evaluate higher-risk grain-handling activities.

Potential JSAs/JHAs may address:

• Grain-bin entry.
• Silo entry.
• Flat-storage entry.
• Clearing choked bucket-elevator legs.
• Conveyor maintenance.
• Auger maintenance.
• Grain-dryer maintenance.
• Hot Work.
• Dust cleanup.
• Truck unloading.
• Railcar unloading.
• Grain loading.
• Equipment servicing.

The analysis should identify job steps, hazards, controls, PPE, and employee responsibilities.

Emergency Action Plan

Covered grain-handling facilities should develop and implement an Emergency Action Plan appropriate to their operations.

Potential emergencies may include:

• Grain-dust fire.
• Explosion.
• Grain engulfment.
• Employee entrapment.
• Equipment fire.
• Chemical release.
• Severe weather.
• Medical emergency.

Employees should understand applicable alarms, emergency reporting procedures, evacuation routes, assembly areas, and accountability procedures.

Employee Training

Employees should receive training before beginning covered work and at least annually as required.

Training should address general safety precautions associated with the facility, including recognition and prevention of hazards involving:

• Grain-dust accumulations.
• Ignition sources.
• Smoking.
• Equipment.
• Housekeeping.
• Hot Work.
• Preventive maintenance.
• Lockout/Tagout.
• Other job-specific hazards.

Employees assigned special tasks should receive additional training appropriate to those duties.

New Employees

New employees should receive required safety training before starting work.

Training should reflect the employee’s assigned tasks and potential exposures.

Employees should not independently perform specialized operations until they have received appropriate training.

Changes in Job Assignment

Additional training should be provided when a change in job assignment exposes an employee to hazards for which the employee has not previously been trained.

This may include assignment to:

• Grain-bin entry.
• Maintenance.
• Hot Work.
• Chemical handling.
• Dust-control equipment.
• Specialized grain-handling equipment.

Grain Storage Structure Entry

Entry into grain bins, silos, tanks, and other grain-storage structures can expose employees to severe or fatal hazards.

Potential hazards include:

• Engulfment.
• Flowing grain.
• Bridged grain.
• Grain buildup.
• Augers.
• Conveyors.
• Mechanical equipment.
• Oxygen deficiency.
• Toxic atmospheres.
• Combustible atmospheres.

Entry should be avoided when work can reasonably be performed without exposing employees to these hazards.

Grain Entry Permit

Before an employee enters a covered bin, silo, or tank, an entry permit should be issued as required unless the employer or authorized representative who would otherwise issue the permit is present during the entire entry.

The permit should certify that required precautions have been implemented before entry.

The permit should remain on file until the entry operation is completed.

Hazardous Energy Before Entry

Before employees enter covered grain-storage structures, equipment that presents a danger to employees inside should be:

• De-energized.
• Disconnected.
• Locked out and tagged.
• Blocked off.
• Otherwise effectively prevented from operating.

Potential equipment may include:

• Augers.
• Conveyors.
• Sweep augers.
• Unloading equipment.
• Other grain-transfer machinery.

Employees should never enter a grain-storage structure while uncontrolled equipment could move grain or expose them to mechanical hazards.

Atmospheric Testing

Before entry into a bin, silo, or tank, the atmosphere should be tested as required for:

• Oxygen.
• Combustible gases or vapors.
• Toxic agents.

Testing requirements depend on the conditions and potential hazards associated with the structure.

Unsafe atmospheric conditions should be corrected before entry when required.

Oxygen Deficiency

An oxygen concentration below 19.5 percent is considered oxygen deficient under the Grain Handling Facilities entry requirements.

When an unsafe oxygen condition exists, appropriate controls should be implemented.

Ventilation should be used as required to eliminate the unsafe condition and continued where recurrence is possible while employees remain inside.

Toxic or Combustible Atmospheres

Where toxic agents or combustible gases or vapors may be present, appropriate atmospheric testing should be performed.

If unsafe conditions are identified, appropriate ventilation and other required controls should be implemented before and during entry.

Employees should not enter an uncontrolled hazardous atmosphere.

Respiratory Protection During Entry

If toxicity or oxygen deficiency cannot be eliminated through ventilation and entry is permitted under applicable requirements, employees should use appropriate respiratory protection.

Respirator use should comply with the facility’s Respiratory Protection Program and applicable requirements.

Flowing Grain

Employees should never enter or remain in grain while grain is flowing from the storage structure.

Flowing grain can pull an employee downward rapidly and create fatal engulfment.

Grain movement should be stopped and hazardous energy controlled before entry.

Walking Down Grain

Employees should never walk on grain to cause it to flow.

Practices sometimes referred to as:

• Walking down grain.
• Stomping grain.
• Walking grain.
• Riding grain.

are prohibited where employees are on moving grain or attempting to make grain flow.

Grain Engulfment

Stored grain can behave like a flowing material when grain is being withdrawn from a structure.

An employee standing on or in flowing grain may become entrapped before being able to escape.

Employees should never rely on their ability to climb or swim out of moving grain.

Engineering and work-practice controls should prevent employee exposure to flowing-grain hazards.

Lifelines and Harnesses

When employees enter a grain-storage structure from a level at or above the stored grain, or stand or walk on stored grain at a depth that creates an engulfment hazard, appropriate protection should be provided as required.

This may include:

• Body harness.
• Lifeline.
• Boatswain’s chair.
• Approved alternative protection where applicable.

The system should prevent the employee from sinking farther than permitted by applicable requirements.

Grain Entry Observer

An appropriately equipped observer should remain outside a bin, silo, or tank during covered employee entry.

The observer should maintain communication with the employee inside through an appropriate method such as:

• Visual contact.
• Voice.
• Signal line.

The observer should be prepared to obtain or provide required assistance.

Rescue Equipment

Equipment specifically suited to the grain-storage structure being entered should be available for rescue operations.

Rescue planning should consider:

• Entry configuration.
• Grain depth.
• Engulfment.
• Mechanical equipment.
• Atmospheric hazards.
• Retrieval.
• Emergency medical response.

Employees should not improvise a rescue that exposes additional employees to uncontrolled hazards.

Observer Training

Employees serving as entry observers should receive appropriate rescue-procedure training, including methods for obtaining additional assistance.

Observers should understand that entering the structure themselves may expose them to the same hazards affecting the entrant.

Bridged Grain

Bridged grain occurs when grain forms a crust or surface that appears solid while an empty space exists beneath it.

An employee stepping onto bridged grain can break through and become engulfed.

Employees should not enter beneath or onto hazardous bridging conditions.

Grain Buildup

Grain may accumulate on the sides of bins or storage structures.

These accumulations can collapse unexpectedly and engulf employees.

Employees should never work beneath a buildup of grain or other material that could fall and bury them.

Flat Storage Structures

Flat storage structures may require employees to enter at ground level to reclaim residual grain.

Employees working in these structures may still be exposed to:

• Engulfment.
• Moving grain.
• Augers.
• Grain piles.
• Mechanical equipment.
• Dust.

Appropriate entry and hazardous-energy procedures should be followed.

Flat Storage Engulfment Protection

Employees standing or walking on stored grain where the grain depth creates an engulfment hazard should use appropriate lifeline or alternative protection as required.

Employees should not stand on moving grain or work beneath unstable accumulations.

Sweep Augers

Sweep augers and other reclamation equipment can create serious entanglement, amputation, and engulfment hazards.

Employees should not enter hazardous areas while equipment is operating unless the operation is specifically permitted and protected under applicable procedures.

Hazardous energy should be controlled when employees are exposed to equipment movement during servicing or entry.

Combustible Grain Dust

Grain dust can create serious fire and explosion hazards.

Combustible grain dust may accumulate on:

• Floors.
• Equipment.
• Motors.
• Bearings.
• Beams.
• Ledges.
• Conveying systems.
• Bucket elevators.
• Dust collectors.

Facilities should control both dust accumulation and potential ignition sources.

Grain Dust Explosion Prevention

A grain-dust explosion generally requires combustible dust, oxygen, an ignition source, and sufficient dust dispersion and confinement.

Potential ignition sources may include:

• Overheated bearings.
• Slipping belts.
• Electrical equipment.
• Welding.
• Cutting.
• Sparks.
• Smoking.
• Hot surfaces.
• Static electricity where applicable.

The facility should control both combustible dust and ignition sources.

Housekeeping Program

Covered facilities should develop and implement a written housekeeping program addressing grain-dust accumulation.

The program should establish:

• Cleaning frequency.
• Cleaning methods.
• Areas requiring priority.
• Dust-control responsibilities.
• Spill-cleanup procedures.

Housekeeping should be integrated into normal facility operations rather than performed only after excessive dust accumulates.

Priority Housekeeping Areas

At grain elevators, priority housekeeping areas include at least:

• Floor areas within 35 feet of inside bucket elevators.
• Floors of enclosed areas containing grinding equipment.
• Floors of enclosed areas containing grain dryers located inside the facility.

These areas require particularly careful dust control.

Grain Dust Action Level

At priority housekeeping areas in grain elevators, fugitive grain-dust accumulations exceeding 1/8 inch should be removed immediately unless the employer has developed and implemented a housekeeping program providing equivalent protection as permitted by the standard.

Facilities should not interpret the 1/8-inch criterion as an acceptable target for routine dust accumulation.

Dust should be minimized wherever practical.

Dust on Elevated Surfaces

Grain dust can accumulate on:

• Rafters.
• Beams.
• Pipes.
• Ledges.
• Equipment.
• Structural members.

Cleaning programs should address both floor-level and elevated accumulations.

Cleaning Methods

Cleaning methods may include:

• Vacuum systems.
• Sweeping.
• Approved dust collection.
• Other methods that minimize dust dispersion.

Cleaning itself should not create an ignition or explosion hazard.

Compressed Air Cleaning

Compressed air should be used for grain-dust cleanup only under conditions permitted by applicable requirements.

Machinery presenting an ignition source in the area should be shut down and other known ignition sources removed or controlled before compressed air is used.

Grain Spills

Grain and grain-product spills should be removed according to the facility’s housekeeping procedures.

Spilled grain can create:

• Slip hazards.
• Trip hazards.
• Dust.
• Equipment interference.
• Pest problems.

Spills should not be allowed to accumulate.

Dust Collection Systems

Dust collection systems should be maintained so they operate as designed.

Systems may include:

• Pneumatic dust collection.
• Filter collectors.
• Local exhaust.
• Enclosed conveying.
• Other dust-control equipment.

A dust-control system does not eliminate the need for effective housekeeping.

Filter Collectors

Applicable fabric dust-filter collectors should be equipped and located according to Grain Handling Facilities requirements.

Monitoring should identify conditions such as excessive pressure drop across filter surfaces.

Malfunctioning dust collection equipment should be corrected promptly.

Preventive Maintenance

Covered grain-handling facilities should implement preventive-maintenance procedures.

Maintenance should include regularly scheduled inspection of applicable:

• Mechanical equipment.
• Safety controls.
• Grain dryers.
• Grain-processing equipment.
• Dust collection equipment.
• Filter collectors.
• Bucket elevators.

Maintenance should also include appropriate lubrication and other servicing.

Equipment Defects

Equipment defects capable of creating fire, explosion, or mechanical hazards should be corrected promptly.

Examples may include:

• Overheated bearings.
• Slipping belts.
• Misaligned belts.
• Malfunctioning dust collection systems.
• Damaged guards.
• Faulty controls.

Equipment should be removed from service when continued operation presents an unacceptable hazard.

Hot Work

Hot Work can provide an ignition source for combustible grain dust.

Covered operations may include:

• Welding.
• Cutting.
• Brazing.
• Similar flame-producing work.

Hot Work should be controlled through the facility’s established permit and fire-prevention procedures.

Hot Work Permit

A Hot Work permit should be issued for covered Hot Work unless an applicable exception under the Grain Handling Facilities standard applies.

The permit should certify that required fire-prevention precautions have been implemented before work begins.

The permit should remain on file until the Hot Work is completed.

Hot Work Areas

Designated welding shops or authorized Hot Work areas located outside the grain-handling structure may be treated differently under applicable requirements.

The facility should clearly identify approved Hot Work locations and establish procedures for work performed elsewhere.

Fire Watch

Where the hazards or applicable Hot Work requirements make a fire watch necessary, designated employees should monitor the work area for fire hazards.

Combustible dust and grain residues should be controlled before Hot Work begins.

Smoking and Ignition Sources

Smoking and other uncontrolled ignition sources should be prohibited where combustible grain-dust or other fire hazards exist.

Employees and contractors should understand facility restrictions before beginning work.

Bucket Elevators

Bucket elevators are critical grain-handling equipment and can create significant fire, explosion, and mechanical hazards.

Potential hazards include:

• Choked legs.
• Belt misalignment.
• Slipping belts.
• Overheated bearings.
• Dust accumulation.
• Moving equipment.

Applicable monitoring, maintenance, and safety procedures should be implemented.

Choked Bucket-Elevator Legs

A choked leg occurs when material buildup stops grain flow and bucket movement.

Employees should follow established clearing procedures.

Inside bucket elevators should not be repeatedly started and stopped, or “jogged,” in an attempt to clear a choked leg.

Clearing Choked Legs

Before employees clear a choked leg, applicable hazardous energy should be controlled.

Procedures should address:

• Electrical energy.
• Mechanical movement.
• Stored grain.
• Unexpected startup.
• Engulfment.
• Dust.

Employees should not enter hazardous equipment areas until required controls are in place.

Bucket-Elevator Belt Alignment

Applicable inside bucket elevators should have required belt-alignment monitoring or another permitted means of maintaining proper belt tracking.

Employees should respond promptly to belt-tracking problems.

Misalignment can contribute to heat, friction, and ignition hazards.

Bearing Monitoring

Bearings associated with grain-handling equipment should be maintained to prevent overheating.

Applicable inside bucket elevators may require bearing-temperature monitoring or other permitted protective measures.

Overheated bearings should be corrected promptly.

Conveyors

Grain conveyors can create:

• Nip points.
• Entanglement.
• Crushing.
• Shearing.
• Falling material.
• Hazardous-energy exposure.

Employees should remain clear of moving conveyor components.

Required guards should remain in place.

Conveyor Guarding

Accessible moving conveyor components should be guarded as required.

Potential hazards include:

• Pulleys.
• Belts.
• Chains.
• Sprockets.
• Nip points.
• Drives.

Guards should not be removed while equipment is operating except where specifically permitted under controlled procedures.

Conveyor Maintenance

Before employees perform maintenance, clear jams, or enter hazardous conveyor areas, applicable energy-control procedures should be followed.

Employees should not rely solely on control switches or emergency-stop devices to prevent unexpected startup during servicing.

Augers

Augers can cause severe entanglement, amputation, crushing, and engulfment injuries.

Employees should remain clear of operating augers.

Open auger areas should be guarded or otherwise protected as required.

Auger Maintenance

Before servicing or clearing an auger:

• Stop the equipment.
• Isolate hazardous energy.
• Prevent unexpected startup.
• Control stored grain.
• Verify the equipment cannot move.

Employees should not reach into an auger to clear material while the equipment is capable of operating.

Grain Receiving

Grain-receiving areas may expose employees to:

• Trucks.
• Railcars.
• Receiving pits.
• Dust.
• Moving equipment.
• Falls.
• Grain spills.

Traffic patterns and employee access should be controlled.

Receiving Pits

Truck and railcar receiving-pit feed openings should be protected by appropriate grates.

Openings should meet applicable Grain Handling Facilities requirements.

Employees should not remove or bypass required pit protection during normal operation.

Truck Unloading

Truck-unloading procedures should address:

• Vehicle movement.
• Driver communication.
• Grain flow.
• Receiving pits.
• Dust.
• Tailgates.
• Hydraulic equipment.
• Pedestrians.

Vehicles should be secured against unintended movement where necessary.

Railcar Operations

Railcar receiving and loading operations may expose employees to:

• Moving railcars.
• Coupling.
• Falling grain.
• Dust.
• Walking-working-surface hazards.
• Equipment movement.

Procedures should coordinate railcar movement with employee activities.

Railcar Movement

Employees should remain clear of moving railcars.

Only appropriately authorized employees should perform or direct railcar movement.

Communication methods should be established before movement begins.

Grain Loading

Employees involved in loading trucks or railcars should remain clear of:

• Moving vehicles.
• Falling grain.
• Loading equipment.
• Dust.
• Unstable surfaces.

Loading systems should be operated within their design limitations.

Grain Dryers

Grain dryers can create:

• Fire hazards.
• High temperatures.
• Dust.
• Mechanical hazards.
• Fuel hazards.

Dryers should be inspected and maintained according to applicable requirements and manufacturer recommendations.

Direct-Heat Grain Dryers

Applicable direct-heat grain dryers should have automatic controls capable of responding to specified unsafe operating conditions.

These controls may include shutting off fuel or stopping grain feed when required operating conditions are lost or excessive temperatures occur.

Safety controls should be maintained in operating condition.

Dryer Fire Prevention

Employees should monitor grain dryers for:

• Overheating.
• Smoke.
• Burning odors.
• Equipment malfunction.
• Grain buildup.

Emergency procedures should address dryer fires.

Grinding and Milling Equipment

Grinding and milling equipment may create:

• Combustible dust.
• Noise.
• Mechanical hazards.
• High temperatures.
• Ignition sources.

Equipment should be appropriately guarded, maintained, and included in housekeeping procedures.

Machine Guarding

Machinery should be guarded to protect employees from hazardous moving components.

Potential hazards may involve:

• Belts.
• Pulleys.
• Gears.
• Shafts.
• Augers.
• Conveyors.
• Mills.
• Fans.

Guards should remain in place during normal operation.

Lockout/Tagout

Hazardous energy should be controlled during covered servicing and maintenance activities.

Potential energy sources may include:

• Electrical.
• Mechanical.
• Hydraulic.
• Pneumatic.
• Gravity.
• Stored grain pressure.

Authorized employees should follow established energy-control procedures.

Contractors

Grain-handling facilities should inform contractors of known potential fire and explosion hazards related to their work and work area.

Contractors should also be informed of:

• Applicable facility safety rules.
• Relevant Emergency Action Plan provisions.
• Permit requirements.
• Other hazards affecting their work.

Contractor activities should be coordinated with facility operations.

Contractor Hot Work

Contractors performing Hot Work should comply with applicable facility permit and fire-prevention procedures.

The facility should coordinate the work so contractors understand grain-dust and ignition hazards.

Contractor Grain Entry

Contractors entering bins, silos, tanks, or other covered structures should coordinate entry procedures with the facility.

Responsibilities for:

• Hazardous-energy control.
• Atmospheric testing.
• Entry permits.
• Observers.
• Rescue.
• Communication.

should be clearly established before entry begins.

Personal Protective Equipment

PPE should be selected according to employee hazards.

Depending on assigned work, PPE may include:

• Safety glasses.
• Goggles.
• Face protection.
• Protective footwear.
• Gloves.
• Hearing protection.
• Respiratory protection.
• Fall protection.
• Protective clothing.

Employees should understand PPE use, care, and limitations.

Respiratory Hazards

Employees may be exposed to airborne:

• Grain dust.
• Mold.
• Fungal material.
• Chemical products.
• Other contaminants.

Potential employee exposures should be evaluated.

Engineering and work-practice controls should be used where appropriate.

Respiratory Protection

Where respirators are required, an appropriate Respiratory Protection Program should be maintained.

Applicable elements may include:

• Hazard evaluation.
• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Maintenance.
• Program evaluation.

Dust masks or other filtering facepiece respirators should not be treated as a substitute for required exposure controls.

Noise Exposure

Grain-handling facilities may contain significant noise from:

• Grain dryers.
• Conveyors.
• Bucket elevators.
• Mills.
• Fans.
• Pneumatic systems.
• Mobile equipment.

Employee noise exposure should be evaluated where hazardous levels may be present.

Hearing Conservation

Where employee exposures reach applicable thresholds, required Hearing Conservation measures should be implemented.

These may include:

• Exposure monitoring.
• Audiometric testing.
• Hearing protection.
• Training.
• Recordkeeping.

Fall Hazards

Employees may work on:

• Bin decks.
• Platforms.
• Catwalks.
• Ladders.
• Grain structures.
• Elevated equipment.

Walking-working surfaces and fall hazards should be evaluated and protected according to applicable requirements.

Bin Decks and Galleries

Access to elevated bin decks and galleries should be maintained in safe condition.

Applicable grain elevators should provide required emergency escape routes from galleries and tunnels.

Employees should keep emergency escape routes clear.

Ladders

Fixed and portable ladders should be maintained and used safely.

Employees should:

• Inspect ladders.
• Maintain secure contact.
• Avoid carrying loads that prevent safe climbing.
• Keep access areas clear.
• Use fall protection where required.

Mobile Equipment

Grain facilities may use:

• Forklifts.
• Loaders.
• Tractors.
• Skid steers.
• Yard vehicles.
• Other mobile equipment.

Only appropriately trained and authorized employees should operate applicable equipment.

Powered Industrial Trucks

Forklifts and other powered industrial trucks should be operated according to applicable requirements.

Operators should consider:

• Pedestrians.
• Loads.
• Visibility.
• Speed.
• Surface conditions.
• Grain dust.
• Hazardous locations.

Pedestrian Safety

Facility traffic plans should reduce interaction between pedestrians and:

• Trucks.
• Railcars.
• Forklifts.
• Loaders.
• Other mobile equipment.

Employees should use designated walkways where provided and remain alert to equipment movement.

Electrical Safety

Electrical equipment should be suitable for the environment in which it is installed and used.

Employees should report:

• Damaged wiring.
• Open electrical enclosures.
• Defective switches.
• Damaged cords.
• Overheating equipment.

Electrical work should be performed by appropriately qualified employees.

Hazardous Locations

Combustible grain dust can affect electrical-equipment selection and installation.

Electrical equipment in classified hazardous locations should meet applicable requirements for the location.

Employees should not introduce unauthorized electrical or ignition-producing equipment into restricted areas.

Static Electricity

Where static electricity can create an ignition hazard, appropriate bonding, grounding, equipment design, or other controls should be used as applicable.

Employees should understand facility procedures for controlling ignition sources.

Fire Prevention

Fire-prevention procedures should address:

• Grain dust.
• Hot Work.
• Smoking.
• Overheated equipment.
• Electrical hazards.
• Grain dryers.
• Maintenance.
• Combustible materials.

Employees should promptly report smoke, burning odors, overheated equipment, or other indications of fire.

Portable Fire Extinguishers

Portable fire extinguishers should be provided and maintained where required.

Employees expected to use extinguishers should receive appropriate training.

Employees should understand when evacuation is safer than attempting to extinguish a fire.

Explosion Response

Employees should not enter or re-enter areas affected by an explosion until the area has been evaluated and determined safe.

Potential hazards following an explosion may include:

• Secondary explosions.
• Fire.
• Structural instability.
• Damaged equipment.
• Electrical hazards.
• Entrapment.

Emergency responders should be provided information regarding facility hazards.

Hazard Communication

Grain-handling facilities may use hazardous chemicals such as:

• Fuels.
• Lubricants.
• Pesticides.
• Fumigants.
• Cleaning products.
• Maintenance chemicals.

An applicable Hazard Communication Program should address labels, Safety Data Sheets, employee training, and chemical information.

Fumigation — When Applicable

Grain fumigation may expose employees to highly hazardous substances.

Where fumigants are used, procedures should address:

• Product hazards.
• Application restrictions.
• Entry restrictions.
• Atmospheric monitoring.
• Warning signs.
• PPE.
• Respiratory protection.
• Emergency response.

Only appropriately trained and authorized employees should perform fumigation-related work.

Pesticides — When Applicable

Grain facilities using pesticides should follow applicable labeling, handling, storage, PPE, and employee-protection requirements.

Pesticides should be stored separately from incompatible materials and protected against unauthorized use.

Confined Spaces

Grain-storage entry should first be evaluated under the requirements specifically applicable to grain-handling facilities.

Other spaces at the facility may separately meet the definition of a confined space or permit-required confined space.

Examples may include:

• Pits.
• Tanks.
• Vaults.
• Process vessels.
• Certain equipment.

Applicable procedures should reflect the particular space and governing requirements.

Manual Material Handling

Employees may manually handle:

• Bags.
• Equipment.
• Parts.
• Supplies.
• Chemicals.

Employees should evaluate load weight, shape, stability, and available grip.

Mechanical assistance or team handling should be used where appropriate.

Ergonomics

Grain-handling tasks may involve:

• Repetitive lifting.
• Bending.
• Reaching.
• Pulling.
• Pushing.
• Awkward equipment access.

Work methods and equipment should be evaluated to reduce unnecessary musculoskeletal stress.

Housekeeping Beyond Grain Dust

Facility housekeeping should also address:

• Grain spills.
• Oil.
• Water.
• Tools.
• Packaging.
• Maintenance materials.
• Blocked access routes.

Floors and walking surfaces should be maintained to reduce slips and trips.

Heat Stress

Employees may work outdoors or near heat-producing equipment.

Heat-illness prevention procedures should consider:

• Drinking water.
• Rest.
• Cooling.
• Acclimatization.
• Workload.
• Weather.
• PPE.

Employees should understand signs and symptoms of heat illness.

Cold Stress

Outdoor grain-handling employees may be exposed to:

• Cold.
• Wind.
• Snow.
• Ice.
• Wet conditions.

Procedures should consider protective clothing, warming opportunities, walking surfaces, and employee monitoring.

Severe Weather

Grain facilities may be affected by:

• Lightning.
• Tornadoes.
• High winds.
• Flooding.
• Snow.
• Ice.
• Extreme temperatures.

Emergency procedures should address hazards appropriate to the facility’s location.

Maintenance Safety

Maintenance employees may perform work on:

• Bucket elevators.
• Conveyors.
• Augers.
• Grain dryers.
• Dust collectors.
• Mills.
• Fans.
• Vehicles.
• Electrical equipment.

Maintenance planning should address hazardous energy, dust, ignition sources, falls, mechanical hazards, and stored material.

Welding and Cutting

Welding and cutting should be performed only under applicable Hot Work procedures.

Before work begins, employees should evaluate:

• Grain dust.
• Grain residue.
• Combustible materials.
• Adjacent equipment.
• Fire protection.
• Ventilation.

Hot Work should not begin until required precautions have been implemented.

Emergency Rescue

Facilities should plan for foreseeable rescue situations.

Potential scenarios include:

• Grain engulfment.
• Grain entrapment.
• Falls.
• Equipment incidents.
• Atmospheric emergencies.

Rescue planning should be completed before an emergency occurs.

Grain Engulfment Rescue

A grain-engulfment rescue can expose rescuers to the same hazards as the victim.

Emergency procedures should emphasize:

• Stopping grain movement.
• Locking out equipment.
• Calling trained rescue resources.
• Preventing additional entry.
• Stabilizing grain where appropriate.
• Controlling atmospheric hazards.

Employees should not make uncontrolled entry into grain in an attempt to rescue a coworker.

First Aid

Appropriate first-aid resources should be available for grain-handling operations.

Employees should promptly report injuries and exposures.

Emergency medical planning should consider facility location and response time.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Grain entrapments.
• Dust fires.
• Explosions.
• Hot Work incidents.
• Equipment malfunctions.
• Unexpected startup.
• Falls.
• Chemical exposures.
• Unsafe dust accumulations.

Prompt reporting helps identify hazards before similar events occur.

Incident Investigation

Significant incidents should be investigated to identify:

• Immediate causes.
• Contributing factors.
• Root causes.
• Corrective actions.

Investigations may consider:

• Housekeeping.
• Dust control.
• Ignition sources.
• Equipment condition.
• Preventive maintenance.
• Lockout/Tagout.
• Entry procedures.
• Training.
• Supervision.
• Contractor coordination.

Root Cause Analysis

Root Cause Analysis may identify underlying factors involving:

• Preventive maintenance.
• Housekeeping schedules.
• Dust collection.
• Equipment design.
• Employee training.
• Permit systems.
• Contractor coordination.
• Hazard recognition.
• Production pressure.
• Inspection systems.
• Corrective-action processes.

Corrective actions should address identified causes rather than simply assigning blame.

Safety Inspections

Periodic safety inspections should evaluate:

• Dust accumulation.
• Bucket elevators.
• Conveyors.
• Augers.
• Grain dryers.
• Dust collection systems.
• Machine guards.
• Electrical equipment.
• Walking-working surfaces.
• Emergency exits.
• Fire protection.
• PPE.

Identified deficiencies should be corrected in a timely manner.

Grain Handling Safety Meetings

Periodic safety meetings may reinforce safe work practices and address current hazards.

Potential topics include:

• Grain engulfment.
• Bin entry.
• Lockout/Tagout.
• Combustible dust.
• Housekeeping.
• Bucket elevators.
• Hot Work.
• Contractor safety.
• Preventive maintenance.
• Recent incidents and near misses.

Recordkeeping

Grain-handling employers should maintain safety and health records required for their operations.

Records may include:

• Employee training.
• Grain-entry permits.
• Hot Work permits.
• Equipment inspections.
• Preventive-maintenance records.
• Dust-control inspections.
• Exposure monitoring.
• Respiratory Protection records.
• Hearing Conservation records.
• Incident investigations.
• Injury and illness records.

Records should be retained according to applicable requirements.

Additional Safety Programs

Depending on grain-handling operations and employee exposures, additional programs may be necessary for:

• Grain Handling Safety.
• Grain Bin & Silo Entry.
• Combustible Dust.
• Lockout/Tagout.
• Machine Guarding.
• Conveyor Safety.
• Auger Safety.
• Bucket Elevator Safety.
• Preventive Maintenance.
• Hot Work.
• Welding & Cutting.
• Confined Space.
• Respiratory Protection.
• Personal Protective Equipment.
• Hearing Conservation.
• Hazard Communication.
• Chemical Safety.
• Fumigation Safety.
• Pesticide Safety.
• Powered Industrial Trucks.
• Mobile Equipment.
• Traffic Control.
• Loading & Unloading.
• Railcar Safety.
• Fall Protection.
• Ladders & Stairways.
• Walking-Working Surfaces.
• Manual Lifting & Material Handling.
• Ergonomics.
• Heat Stress Prevention.
• Cold Stress.
• Severe Weather.
• Emergency Action Plan.
• Fire Prevention.
• First Aid.
• Contractor Safety.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the facility’s grain products, processes, storage structures, machinery, chemicals, and employee exposures make them applicable.

Building a Grain Handling Safety Manual

A useful Grain Handling Safety Manual should reflect the facility’s actual grain-handling operations.

A commercial grain elevator may require extensive procedures for grain receiving, bucket elevators, grain bins, engulfment prevention, grain-dust housekeeping, truck and rail operations, grain dryers, Hot Work, and preventive maintenance.

A feed mill may require greater emphasis on grinding and processing equipment, conveyors, dust control, machine guarding, Lockout/Tagout, ingredient handling, and maintenance.

A flour or dry corn mill may require substantial procedures for combustible dust, milling equipment, pneumatic conveying, dust collection, electrical equipment, Hot Work, and ignition-source control.

A grain-storage facility may require greater emphasis on bin and silo entry, engulfment, augers, conveyors, stored grain, atmospheric testing, and emergency rescue.

A facility performing fumigation may require additional procedures for toxic substances, atmospheric monitoring, respiratory protection, restricted entry, PPE, and emergency response.

The safety manual should therefore be based on the grain-handling work actually performed rather than automatically assigning every grain-related program to every facility.

Customized Grain Handling Safety Manuals

A Grain Handling Safety Manual can be developed around the facility’s grain bins, silos, flat storage structures, bucket elevators, conveyors, augers, grain dryers, mills, dust collection systems, trucks, railcars, mobile equipment, maintenance operations, employees, and other occupational hazards.

The finished manual may incorporate applicable programs for Grain Bin Entry, Combustible Dust, Lockout/Tagout, Machine Guarding, Conveyor Safety, Hot Work, Preventive Maintenance, Respiratory Protection, PPE, Hearing Conservation, Powered Industrial Trucks, Emergency Action Planning, Incident Investigation, and other hazards associated with grain-handling operations.

This provides grain elevators, feed mills, flour mills, grain-storage operations, and other grain-handling employers with a practical safety manual organized around the work their employees actually perform.