1. Flowing Grain Dangers Sponsors: Indiana Grain and Feed Association
11/15/2018
Flowing Grain Dangers
Developed by:
Matt Roberts, Grain Entrapment Consultant
Bill Field, Purdue University’s Agricultural Safety and Health Program
Sponsors:
Indiana Grain and Feed Association
ISDA
Indiana Corn Marketing Council
Indiana Soybean Alliance
Indiana Rural Safety and Health Council
Thank everyone for coming.
Introduce yourself.
Mention the title of the presentation, developers, and the sponsors.

2. Flowing Grain Dangers
11/15/2018
Notice!
This lecture does NOT address current OSHA requirements for grain handling
Meant for non-OSHA regulated agricultural worksites
This slide is a disclaimer. The presentation does not cover the information related to OSHA regulations for entry into confined spaces within the commercial grain industry. The information is best suited to be delivered to non-OSHA regulated farms with 10 or fewer employees.

3. Outline Intro What do we know? Seven types of entrapment
Flowing Grain Dangers
11/15/2018
Outline
Intro
How big is the problem?
What do we know?
Frequency
Medium
Sites Involved
Contributing Factors
Seven types of entrapment
Responding to entrapment
Steps to follow
Removing grain
Rescue tubes
Rescue hazards
Summary
Key ways to prevent entrapment
Go over the outline with the audience. This is the road map that you will be using as you go through the lecture. It lets the audience know what to expect and when to expect it.

4. Flowing Grain Dangers
11/15/2018
Definitions
Flowable agricultural material – free flowing agricultural crops or material including grain
Engulfment - events in which an individual is submerged, i.e. fully buried in agricultural flowable material, such as corn, small grains, or feed
Entrapment - used in a broader way to describe events in which an individual is trapped, possibly due to engulfment, inside a structure considered a confined space such as a silo, bin, grain transport vehicle, outdoor pile, or bunker silo, where self extrication is not possible
Confined Space – (in brief) an area large enough for a worker to enter to perform tasks, not designed for continuous employee occupancy
Some wording presented throughout the presentation may not be familiar to your audience. This slide is an opportunity to get everyone in the audience on the same page when it comes to using the terms correctly. This slide may also be useful for the instructor so that he or she can apply them consistantly throughout the lecture.

5. Flowing Grain Dangers
11/15/2018
How big is the problem?
Since 1964 Purdue University has recorded over 700 cases of flowing grain entrapment nationwide
International cases have also been documented
This slide lays the ground work for the presentation by giving the audience an idea of how many entrapments have been recorded over the years. It is important to note that Purdue University has, by far, the largest and most extensive database currently maintained on grain related entrapments known as the Purdue Grain Entrapment Database. You will notice that the database only goes back to This is the earliest recorded case of grain entrapment researchers have been able to document in the United States. It is also important to point out that the database is not comprehensive. It is believed that many cases of entrapment, especially those not resulting in a fatality, go unreported. In other words the data base provides the “best” possible picture of the problem.

6. Flowing Grain Dangers
11/15/2018
Frequency and outcome
Average between documented entrapments per year over past 4 decades
Frequency increasing
In % of documented grain entrapments resulted in death
Many non-fatal incidents go unreported
This information was also pulled from Purdue’s Grain Entrapment Database. It discusses how many entrapments have been documented each year (on average). As noted, many non-fatal cases go unreported. Often times, if first responders are not called to a scene there is no mention of the entrapment in the media, so the entrapment is not publicized. In certain situations the freed entrapment victim may be afraid to report the incident to their employer or to others in the community due to potential embarrassment.

7. Mediums where entrapments occur
Flowing Grain Dangers
11/15/2018
Mediums where entrapments occur
At least 45% of known entrapments involve corn
Entrapments have been document in: soybeans, wheat, oats, sunflower, alfalfa seed, malted barley, milo, processed feed and rice
This slide shows that entrapments have been documented in almost every type of grain or oilseed. However, the most entrapments occur in shelled corn. In many cases, the type of grain was unknown, so it is likely that the percentage of incidents occurring in shelled corn is much higher. It is believed that fewer incidents occur in soybeans and small grains because they tend to be harvested and stored at lower moistures contents and are less likely to go out-of-condition.

8. Entrapments by geographic location
Flowing Grain Dangers
11/15/2018
Entrapments by geographic location
As mentioned in the previous slide, shelled corn is the primary medium for entrapment. On this map you’ll notice that many of the recorded grain entrapments have come from the Midwest where corn is predominantly grown. You’ll also note that Indiana has the highest number of entrapments. This higher frequency is because Purdue has been more aggressively attempting to document grain entrapment, over the past 30 years, than any other land-grant institution. It stands to reason that over the years Purdue has been able to document more grain entrapments in Indiana than it has other states. Also, prior to the age of the internet, Purdue had to rely on the reporting that was coming from other land-grant universities, or the print media, for the tracking of entrapments in other states.

9. Documented contributing factors
Flowing Grain Dangers
11/15/2018
Documented contributing factors
#1 identified cause of entrapment was out-of-condition grain
High capacity grain handling systems
Working alone
Relaxed compliance with workplace safety regulations
Lack of knowledge concerning the risk
Of all the factors that contribute to grain entrapment, the number one reason for grain entrapment is spoiled or out-of-condition grain. Therefore, it is very important that grain be properly maintained to avoid spoilage. One of the best reasons for maintaining good grain quality (besides the economic aspect) is for safety reasons.
The other contributing factors relate to the changing technology and workforce related to grain handling and storage. Greater volumes of grain are being handled at higher speeds and with fewer workers.

10. Types of documented entrapments
Flowing Grain Dangers
11/15/2018
Types of documented entrapments
Flowing grain
Collapse of horizontally crusted grain surface
Collapse of vertically crusted grain surface
Grain transport vehicles
Use of grain vacuum machines
Outdoor pile avalanche
Storage structure failure
Nearly all grain-related entrapments fall into one of the following seven categories.
In the following slides graphics are used to represent each of the seven types of entrapment listed.

11. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Unloading entrapment typically occurs when an individual enters a storage structure with the structure’s unloading equipment in operation. Often times the reason for entry is that there is spoiled grain that has plugged the center unloading well. The person enters the structure and attempts to break up the blockage. If the unloading equipment is running and the block is freed, the flow of grain resumes thereby entrapping the individual in the flow of grain. The victim is quickly pulled to the bottom of the grain mass and is usually located directly over the opening from which the grain is being removed.
Graphic used with permission from Liberty Rescue Systems

12. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
This graphic depicts just how fast entrapment can happen. As shown in the slide, it only takes 15 seconds for an individual to become entrapped to the waist (the point where they cannot free themselves). Once the victim is buried in grain to above the knees, it becomes increasingly difficult for the individual to free themselves. Once grain is above the waist, self-extrication is virtually impossible.
Graphic used with permission from Liberty Rescue Systems

13. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Bridging entrapment is the result of spoiled grain forming a crusted layer on the top of the grain mass. Sometimes grain can be removed from a storage structure and the crusted layer on top will remain. This gives the illusion that the grain surface is safe to walk on. The graphic depicts what can happen if an individual walks on the crusted surface with a void below. Important!! This void does not need to be very big to cause entrapment. A void only 3 feet deep can result in an entrapment situation.
Graphic used with permission from Liberty Rescue Systems

14. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Avalanche entrapment occurs when spoiled grain clings to the walls of storage structures. Literally tons of grain can be suspended in the air in a highly unstable situation, and, the grain can be displaced by a worker probing from below causing him or her to be buried by a sudden avalanche of grain.
Graphic used with permission from Liberty Rescue Systems

15. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Entrapments in free standing piles of grain typically occurs when an individual is walking on a pile and disrupts the surface of the grain. Sheets of grain can let loose and tumble down onto an unsuspecting victim. This not only can happen to workers inspecting or tarping piles, but also to children playing on even relatively small piles of grain.
Graphic used with permission from Liberty Rescue Systems

16. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Transport vehicle entrapment usually occurs when a child is playing inside the vehicle and the vehicle is either loaded or unloaded thereby trapping the child. The possibility of a child being buried inside a transport vehicle by equipment dumping grain into that vehicle has become a greater risk with larger capacity equipment. For instance, combines of today are capable of unloading grain at 4 bushels per second. That’s nearly 225 pounds of corn in one second, and some grain carts are even faster! Rule of thumb, kids, or workers, should never be allowed inside grain transport vehicles.
Children are also entrapped when they are allowed on top of the grain in transport vehicle and the bottom outlet is opened allowing the child to be drawn into th egrain flow and possibly becoming wedged into the outlet.
Graphic used with permission from Liberty Rescue Systems

17. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Although rare, unintended release of grain can bury workers. It can result from aging bins bursting, uneven unloading of the structure that causes side loading that can result in the structure splitting, or the inner safety doors of the structure not being properly installed prior to filling. Great care should be taken if there is any evidence of structural failure or grain leakage around any opening.
Graphic used with permission from Liberty Rescue Systems

18. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
Entrapments caused by the use of grain vacuums can occur when an operator losses focus or becomes fatigued and allows the nozzle of the vacuum to begin removing grain from around and beneath their feet. In a matter of seconds the operator can be pulled into the grain mass. Great care should be taken and safety valves on the nozzle should be in place when operating these machines. All activities involving grain vacuums should include two people in order to have one available to shut down the power in the event of an entrapment.
Graphic used with permission from Liberty Rescue Systems

19. Responding to Grain Entrapment
Flowing Grain Dangers
11/15/2018
Responding to Grain Entrapment
Partial entrapment
Complete engulfment
Entanglement in equipment
The primary emphasis of grain handling safety should be in prevention. If grain is kept in good condition, safe work practices are followed, and equipment is properly maintained the risk of entrapment will be less and the need for grain rescue operations will be nearly eliminated. However, it is important that everyone involved in grain handling and storage operations be familiar with appropriate first response strategies in the event of grain entrapment.

20. Responding to complete engulfment
Flowing Grain Dangers
11/15/2018
Responding to complete engulfment
Stop – Do not enter structure
Shut down and lock out equipment
Activate local emergency fire rescue services
Turn on aeration fans
Assemble employees
Assess situation and resources
Implement situation-specific action plan
Source: Don’t Go With the Flow, (NGFA)
In the event of an entrapment there are some very important things to keep in mind. (The numbers below correspond with the numbers above)
Stop - Entering structure may cause you to become entrapped or cause the victim to be buried deeper.
Shut down all equipment at the facility and lock it out so it can not be turned on accidentally.
Call 911
Turn on aeration fans - just because a person is fully buried doesn’t mean they are dead. Turning of aeration of the structure where the accident took place can help give the entrapped victim some fresh air and a sense of hope.
Assemble employees - take a head count of everyone at the farm, see who is there and who is missing
Assess the situation - see what equipment you or neighbors have that might be useful to the fire department (i.e. loaders, trucks, grain vacuums, knowledge of the facility, etc…)
Implement plan - with the direction of the fire department implement their action plan (this may mean staying out of their way)

21. Two primary rescue techniques
Flowing Grain Dangers
11/15/2018
Two primary rescue techniques
Removing the grain from around the victim
Utilize a grain retaining wall or rescue tube to extricate victim from grain mass
If a victim is fully engulfed, grain must be removed from the structure. On smaller structures of less than 20,000 bu., this is often accomplished by cutting 4 evenly placed holes around the storage structure and allowing the grain to spill out. Care must be taken to not side load the bin, and, there will likely be a large amount of grain to move away from the outside of the storage structure. The higher the cuts are placed the better. This allows more grain to be removed more quickly without it piling up too much outside of the structure. In some cases a grain vacuum unit may be used to remove grain from around the victim.
If a victim is partially entrapped, building a grain retaining wall or using a grain rescue tube typically results in a more timely and effective rescue. A grain retaining wall simply keeps additional grain from further burying the victim and enables rescuers to remove the grain from inside the retaining wall thereby freeing the entrapped victim. Important!!! Only trained first responders should attempt a grain rescue.

22. Partial entrapment rescue
Flowing Grain Dangers
11/15/2018
Partial entrapment rescue
Don’t jump into the bin, the victim could be buried deeper by inflowing grain
Victim cannot be pulled free without injury
If an individual is partially entrapped the first reaction of co-workers, family members, or friends, is to jump into the storage structure and try to pull an individual out. This is very dangerous. Jumping into the storage structure could cause more grain to slide down onto the entrapped victim. Also the person entering the structure runs the risk of entrapment.
If a victim is entrapped he or she cannot simply be pulled free. The grain must first be removed from around the individual. There have been cases where entrapment victims have been severely injured and killed when rescue attempts were made that included tying a rope around the underarms of the entrapped victim and the pulling on the rope by mechanical means (i.e. hoisting equipment).

23. Graphic used with permission from Liberty Rescue Systems
Flowing Grain Dangers
11/15/2018
This graphic depicts the amount of force needed to pull a 165 Lb person out of grain at various depths. Now imagine how much force it would take to pull a person that weighs 265 Lbs out of grain, it would result in severe physical injuries.
Graphic used with permission from Liberty Rescue Systems

24. Partial entrapment rescue
Flowing Grain Dangers
11/15/2018
Partial entrapment rescue
Don’t waste time digging without a grain retaining device
Construct a grain retaining device or use a rescue tube; secure and stabilize victim
Again, if a person is partially entrapped build a grain retaining wall or use a grain rescue tube. A grain rescue tube is a portable unit that can be assembled and inserted around the victim to protect him or her from the surrounding grain. Once in place the grain within the tube can be removed, freeing the victim.

25. Grain retaining device on-site materials
Flowing Grain Dangers
11/15/2018
Grain retaining device on-site materials
Backboards
Plywood
Metal roofing
Grain retaining walls do not need to be elaborate or expensive. In the picture on this slide there is an individual holding a ring that is part of a round hog feeder. He was rescued with the ring he is holding.

26. Flowing Grain Dangers
11/15/2018
Liberty Rescue Tube
The photographs in this slide show the commercially Liberty Rescue Tube. This device has been used in at least three successful rescues.
Photos used with permission of Liberty Rescue Systems, Inc.

27. Potential rescue hazards
Flowing Grain Dangers
11/15/2018
Potential rescue hazards
Bin steps and ladders (350 Lb limit)
Flowing grain, secondary entrapment
Hazardous atmosphere, dust, and chemicals
Overexertion
Exposure to grain handling equipment
There are several hazards associated with grain rescue. The risk of injury is high. It is best to leave it up to the professionals.

28. Summary – Preventing Grain Entrapments
Flowing Grain Dangers
11/15/2018
Summary – Preventing Grain Entrapments
Never enter structure while unloading
Only enter a structure with an observer present
Do not enter bin if grain is bridged or caked on walls
Ensure stored grain maintains quality
Think before you act
The best entrapment rescue is one that never happens. Entrapments are preventable
Most entrapments happen when people get in a hurry. Before you do something that may endanger your health think of the consequences it may have on loved ones, friends, and neighbors.
Never enter a bin where there are flow problems or with unloading equipment operating.
Make sure grain does not spoil. Spoiled grain causes more entrapments than anything else.

29. Questions? E-mail us at: field@purdue.edu mroberts@purdue.edu
Flowing Grain Dangers
11/15/2018
Questions?
us at:
Dr. Bill Field
Mr. Matt Roberts
Or contact Purdue’s Agricultural and Biological Engineering Dept and ask to speak with someone from the Purdue University Safety and Health Program

30. Flowing Grain Dangers
References
11/15/2018
D.E. Maier, W.E. Field, S.A. Freeman, Don’t Go With the Flow Educational Resource Kit. National Grain and Feed Association, West Lafayette, IN.
C.V. Schwab, Inflow Velocity and Forces Acting on a Person Trapped in Enveloping Flow of Granular Materials. Masters, University of Kentucky, Lexington.
Roberts, et al., Summary of Flowable Agricultural Material Entrapment Rescue Strategies –
Responding to Agricultural Emergencies, 1999 – NRAES
References for locations where information was acquired for this presentation.