Reprinted from GRAIN JOURNAL March/April 2020 Issue
Not since the 2009-10 growing season have we fielded more questions concerning grain that has gone out of condition and won’t flow out of storage.
The reasons for out-of-condition grain are no longer important. Whether it was insufficient drying of the grain, excess foreign material, or a leaking bin roof, the issue now is grain flow.
In some cases, a crusted layer has formed on the surface of the grain or within the grain mass, causing a void above the outlets as grain is removed. If the crusted grain then breaks up, the chunks can block the outlets, reducing or stopping flow.
In other cases, vertically crusted grain can cling to the walls of the structure or form free-standing piles that can involve tons of grain that can collapse without warning.
As is well-documented in these annual summaries, there is a direct correlation between out-of-condition grain and increased risk of a worker being exposed to an entrapment situation.
In other words, when a farmer or elevator employee has to fight to get the grain to flow out of the structure, there is a strong temptation to bypass safe work practices and enter the structure to make attempts to keep the grain flowing.
If the grain won’t flow, it’s already too late to debate what was or was not done last fall to cause the problem.
Responding to Out-of-Condition Grain
The issue at hand is to remove the grain without putting anyone at risk of entrapment. The following are some steps to consider. They may not be the most profitable options but are intended to keep everyone safe.
1. Never enter a bin where there is evidence of crusting on the surface or within the grain mass. If grain is removed from the structure and the surface has not flowed inward, stay out! This is a clear sign that crusting is present and a void has formed over the outlet.
2. If there are any signs that the grain is or has gone out of condition, it needs to be removed immediately. The condition of the grain will not improve if left in storage and will only worsen. As warm weather arrives, biological and insect activity will increase, leading to even more spoilage.
3. Perform all observations or unplugging efforts from outside the bin, at the top access hatch. Again, if there is evidence of crusting, spoilage, or excessive heating, stay out! The risk is too great. In some cases, long pipes, rebar, or other probes can be inserted into the grain mass to break up crusted grain or trash that is plugging the outlet. Watch out for overhead power lines when handling these long probes.
4. If the grain has become so crusted that it cannot be removed according to the bin manufacturer’s recommendations, contact a professional grain salvage service with experience and equipment to break up and remove out-of-condition grain. These services are not inexpensive but can save lives.
5. Do not cut open the side walls of a bin without consulting the manufacturer. Cutting into a bin could damage the structural integrity of the bin or result in uneven loading that causes the structure to fail and collapse.
This article is taken from the 2019 Summary of U.S. Agricultural Confined Space-Related Injuries and Fatalities, published by Purdue University Agricultural Safety and Health Program in mid-March. For more info on the complete report, see p. 64.
