Get ahead of harvest injuries: Prepping for safety pays off

By John Shutske, Extension agricultural safety specialist and professor

Fall harvest is when most farms hit double-time speed. It is also when safety risks climb fast. Whether you are chopping silage, combining, or cutting hay, the days are long and the pressure is real. Tight schedules, uncertain weather, and long hours create a hazardous mix.

Each year, we see injuries that could have been avoided with better planning. Some are minor. Others change lives forever. Some farms never fully recover, financially or emotionally.

Safety matters for your crew, your family and your farm’s future. The good news is that most serious incidents are predictable and preventable. When you address known risk factors and hazards early, you avoid costly surprises later.

Think like a pilot AND a farmer

You wouldn’t fly a plane without a preflight check. Pilots and their crews go over every inch of their machine because safety starts with preparation. The same goes for harvest equipment.

Do a walk-through of every machine before crunch time begins. Check combines, choppers, tractors, trucks, wagons, blowers and grain augers.

Ask yourself:

• Are all shields and guards in place?
• Do lights, reflectors, turn signals and SMV emblems meet federal standards?
• Have you replaced worn hydraulic hoses, belts and tires?
• Are seatbelts working on all highway vehicles and rollover protective structure (ROPS)-equipped tractors?
• Are fire extinguishers fully charged and easy to access?

Handle repairs now. In the middle of harvest, pressure builds and corners get cut. That is when entanglements, crushing injuries or falls happen most.

Invisible dangers around silage

For dairy farms, silo gas is a deadly, invisible hazard. Even brief exposure can cause serious lung damage. In some cases, it’s fatal.

This gas forms in all silage systems, not just tower silos. Bunkers, piles and bags also release gas, especially in calm fall weather when it can collect close to the ground.

Air movement is critical. For tower silos, run the blower for 30 minutes or more before entry, but only after the initial high-risk period has passed. Stay clear of enclosed or still, low-lying areas near any silage storage (including bunkers, piles, or bags). If you must enter a confined space, use ventilation, test the air and follow confined space entry and lockout-tagout safety procedures. Never work alone and make sure one or more people on your team have the training and knowledge necessary to accomplish the task safely.

Bunker silos: Slope safety and rollovers

Packing silage into a bunker or pile requires the right tractor and setup. Every year, farmers are hurt or killed by rollovers, often because of steep surfaces or unstable equipment.

Use tractors with ROPS, working seatbelts, wide fronts and duals. Front-wheel assist and proper ballast help too.

Back up slopes for better control. Keep pile slopes no steeper than 3 feet of run for every 1 foot of rise. The “ramp” up to the top of a 20-foot-tall pile should stretch at least 60 feet. Steeper slopes raise the rollover risk.

Feedout hazards

After harvest, the dangers are not over. Bunker face collapses kill farmers and workers every year. Never stand near the face of a pile. Maintain a distance of at least three times the height of the wall.

Equip loaders with overhead protection. Keep visitors and children far from feeding and storage areas. What looks like a fun place to watch machines is often one of the most dangerous parts of the farm. That includes climbing on small piles of feed or silage.

Train your crew the right way

Do not assume workers know what to do. Even experienced people need reminders. New hires, part-timers, and custom operators may not be familiar with your setup or expectations.

Take time to review key steps and safety procedures. Show people how to run equipment properly and what to do when things go wrong. Clear training builds a stronger safety culture.

Ensure that workers have reliable means of communication. Radios sometimes work better than phones in rural areas. If phones are used, discuss rules to prevent texting or calls while driving or operating machinery.

How safety pays

There is a strong business case for safety. The costs of an injury are high. Medical bills, lost time, equipment damage, legal issues and higher insurance premiums all subtract from the bottom line. One serious injury can wipe out a year’s profits…or an entire operation.

By comparison, safety investments are low-cost and high-return. Updating equipment, replacing shields and handing out visibility gear are small expenses. Routine maintenance and training are far cheaper than dealing with a major injury.

Many farms report significant savings from safety investments. Benefits accrue from fewer breakdowns, improved employee retention, enhanced performance and reduced risk – all of which support the bottom line.

Keep learning and stay sharp

This article is just a starting point. Every farm has different risks based on its team, equipment and layout. Keep learning. Use tools and resources from Extension, your insurer, consultants, and safety organizations.

Make safety part of your planning. Use checklists, hold monthly safety training conversations and track near misses. The more your team sees you lead on safety, the more seriously they’ll take it.