Farm machinery safety

Agriculture has the highest rate of fatal injury of any UK industry sector. Transport and vehicles are the largest single cause of death on farms, and contact with machinery is another leading cause of death and serious injury. Every year, farmers, farm workers, and family members are killed or seriously injured by tractors, PTOs, telehandlers, and other farm equipment.

This guide explains your legal duties under health and safety law, and provides practical guidance on keeping everyone safe around farm machinery.

Why farm machinery safety matters

• Fatal injuries: Around 25-30 people die in GB agriculture each year (including members of the public), with transport the largest single cause and machinery contact another major cause
• Serious injuries: Hundreds more suffer life-changing injuries including amputations, crushing injuries, and burns
• Common victims: Not just farm workers - family members (including children), contractors, and visitors are frequently involved
• Prosecution risk: HSE actively investigates farm deaths and can bring criminal prosecutions with unlimited fines

Most farm machinery accidents are preventable through proper training, maintenance, safe systems of work, and effective guarding.

Legal requirements: PUWER and LOLER

Two key sets of regulations govern farm machinery safety:

Provision and Use of Work Equipment Regulations 1998 (PUWER)

PUWER applies to all work equipment, including all farm machinery from hand tools to combine harvesters. As the employer or self-employed person, you must ensure that:

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)

LOLER applies to lifting equipment used on farms, including:

• Telehandlers (telescopic handlers)
• Forklift trucks
• Tractor front-end loaders
• Workshop hoists and cranes
• Lifting accessories (chains, slings, shackles)

Key LOLER requirements for farms

Risk assessment for machinery

You must conduct a suitable and sufficient risk assessment for all machinery used on your farm. This is a legal requirement under the Management of Health and Safety at Work Regulations 1999.

What to assess

For each machine, consider:

• Who uses it? Are they trained and competent? Are they old enough?
• What hazards exist? Moving parts, entanglement, crushing, shearing, cutting, ejected material
• Are guards in place? And are they being used?
• Is it maintained? Records, inspection intervals, known defects
• What could go wrong? Blockages, breakdowns, slopes, uneven ground
• Who else could be harmed? Family members, visitors, contractors, passers-by

Record your assessment

If you have 5 or more employees, you must record your significant findings. Even if you have fewer employees, keeping written records is good practice and demonstrates due diligence if there is an incident.

Review your risk assessment:

• When you buy new or different machinery
• After any accident or near-miss
• When work practices change
• At least annually

Tractor safety

Tractors are involved in more fatal farm accidents than any other machine. The two main causes of death are:

1. Overturning - tractor rolls over, crushing or trapping the driver
2. Being run over - driver or bystander struck by moving tractor

Rollover protective structures (ROPS)

A safety cab or roll bar (ROPS) is designed to provide a protective zone for the driver if the tractor overturns.

Legal requirements:

• Tractors must be fitted with a ROPS (safety cab or roll bar) where there is a risk of rollover
• You may only use a tractor without ROPS in low-risk situations such as inside buildings or orchards where specific exemptions exist
• Even with exemptions, you must complete a risk assessment to justify not fitting ROPS

Seatbelts

Where ROPS is fitted and there is a risk of overturning, you must also have a seat belt or restraint system fitted if reasonably practicable.

Why seatbelts matter: A ROPS only protects you if you stay within the protective zone. Without a seatbelt, drivers are thrown from the cab or crushed against the roll bar. Wearing a seatbelt greatly reduces the risk of death in a rollover.

Safe Stop procedure

The Safe Stop procedure must be followed every time you leave the tractor seat, even briefly:

The Safe Stop procedure prevents tractors from rolling away or moving unexpectedly. Many fatal accidents occur when drivers are run over by their own tractors after dismounting without properly securing the vehicle.

Working on slopes

Overturning accidents are not confined to steep hills - they happen on gentle slopes, near ditches, on ramps, and on uneven ground.

Before working on slopes:

• Assess the terrain - look for ditches, soft ground, hidden obstacles
• Check the slope gradient - use a slope indicator if available
• Choose an appropriate tractor with ROPS and seatbelt fitted
• Consider weather conditions - wet or frosty ground increases risk

Safe driving techniques:

• Drive up and down slopes, not across them where possible
• Avoid sudden braking, accelerating, or turning
• Lower implements when turning
• Be aware of the effect of towed loads on stability
• Reduce speed and increase caution in wet conditions

Power take-off (PTO) safety

A tractor power take-off (PTO) and PTO drive shaft are extremely dangerous if not correctly guarded. Every year people are killed or seriously injured in PTO accidents. The rotating shaft can catch loose clothing, hair, or limbs and pull the person into the machine with devastating force.

PTO accidents are almost always fatal or result in severe injury. The shaft rotates at 540 or 1000 rpm - a victim can be drawn in and wrapped around the shaft in less than a second.

PTO guarding requirements

All PTO shafts must be fully guarded at all times. Check that guards are:

• Complete: Covering the entire length of the shaft including universal joints
• Undamaged: No cracks, holes, or missing sections
• Properly fitted: Guards must rotate freely around the shaft
• Secured: Both ends restrained to prevent rotation with the shaft

Guard components required:

• Tractor PTO shield: The "U" guard covering the tractor PTO stub
• Machine input shield: The "O" guard on the machine side
• Main shaft guard: The tubular guard covering the drive shaft

Safe working with PTOs

• Never operate PTO-driven equipment without all guards in place
• Never step over a rotating PTO shaft
• Never attempt to clear blockages without stopping the PTO and engine
• Never wear loose clothing near PTO equipment
• Always disengage the PTO and switch off the engine before leaving the tractor seat
• Always check guards before starting work each day
• Never use adaptors to connect incompatible shafts (e.g., 21-spline 1000rpm to 6-spline 540rpm)

PTO master shields

The tractor PTO master shield (U guard) must be fitted at all times, even when the PTO is not being used. This prevents accidental contact with the exposed PTO stub.

Combine harvester safety

Combine harvesters present multiple serious hazards including:

• Cutter bar and reel: Risk of being drawn into cutting mechanism
• Augers: Drawing-in and entanglement hazards in header and grain tank
• Straw chopper: High-speed rotating knives
• Fire: Combines are significant fire risks due to dust, chaff, and hot components
• Falls from height: When climbing on the machine for maintenance or checking crop
• Run-over: Large blind spots and low awareness of bystanders

Safe operating procedures

• Never attempt to clear blockages while the machine is running
• Always stop the engine, remove the key, and wait for all moving parts to stop before approaching the header or other dangerous parts
• Never climb into the grain tank unless the engine is off and all augers are stationary - grain can engulf a person in seconds
• Carry fire extinguishers and check for chaff buildup around the engine daily
• Be aware of overhead power lines - the unloading auger and header in transport position can contact lines
• Use three-point contact when climbing on the machine
• Keep bystanders away from operating combines

Clearing blockages

Blockages in the header, feeder, or straw chopper are common. The temptation is to clear them quickly without fully stopping. This causes many serious injuries.

Safe blockage clearing procedure:

1. Stop the machine completely
2. Disengage the header and all drives
3. Switch off the engine
4. Remove the key
5. Wait for all rotating parts to stop (this may take 30+ seconds for some components)
6. Clear the blockage using appropriate tools, not hands
7. Check guards are replaced before restarting

Telehandler and loader safety

Telehandlers (telescopic handlers) and front-end loaders are involved in many serious and fatal farm accidents. Risks include:

• Overturning: Particularly when lifting at full extension or on slopes
• Run-over: Poor visibility, especially when reversing or carrying large loads
• Falling objects: Loads becoming unstable or falling from height
• Crushing: People trapped between machine and fixed objects

Operator requirements

Telehandlers and forklifts must only be driven by authorised, trained, and competent people. The driving characteristics of a telehandler differ greatly from other farm vehicles.

Training is essential for:

• New operators (even experienced tractor drivers)
• Young workers starting to use material handlers
• Anyone moving between different machine types

Safe operating practices

• Know the load chart: Understand how lift capacity reduces at greater extension
• Position loads correctly: Keep loads close to the ground when travelling
• Use stabilisers: Deploy stabilisers for heavy or high lifts where fitted
• Check all around: Look around and sound the horn before moving off
• Travel in reverse: If the load obscures forward vision
• Avoid slopes: Telehandlers are particularly unstable on slopes
• Use correct attachments: Only use attachments approved by the manufacturer

Lifting equipment examination

Telehandlers used for lifting require thorough examination under LOLER:

• Every 12 months for lifting equipment
• Every 6 months for lifting accessories (slings, chains, shackles)
• Every 6 months if used for lifting people

ATV and quad bike safety

All-terrain vehicles (ATVs) including quad bikes are popular on farms but cause many fatalities each year. Most deaths are caused by head injuries when riders are thrown off after the vehicle overturns.

Critical safety requirements

• Always wear a helmet: Helmets would have prevented most quad bike fatalities in the UK
• Get proper training: Quad bikes require specific riding techniques ("active riding") to maintain stability
• Never carry passengers: The long seat is for weight shifting, not passengers. Carrying passengers is illegal on sit-astride ATVs
• Never carry children: It is illegal to carry children as passengers on ATVs
• Do not overload racks: Excessive or poorly distributed loads cause instability
• Check tyre pressures regularly: Even small variations in pressure significantly affect stability
• Match machine to terrain: Do not exceed the machine's capabilities on slopes or rough ground

Side-by-side utility vehicles

Side-by-side utility vehicles (sit-in vehicles with steering wheels) have different characteristics from sit-astride quad bikes:

• Can carry passengers if fitted with passenger seats
• Often have ROPS - always wear the seatbelt
• May feel more stable but can still overturn if misused
• Weight distribution on cargo bed still critical

Workshop machinery safety

Farm workshops contain many hazards beyond the main mobile farm equipment. Key workshop machinery hazards include:

Common workshop hazards

• Bench grinders and abrasive wheels: Use correct wheel for the job, adjust tool rests close to the wheel, wear eye protection
• Welding equipment: Arc-eye risk to bystanders, fire risk, fume extraction needed
• Vehicle hoists and jacks: Must be rated for the load and properly maintained
• Compressors and pressure equipment: Risk of burst, proper maintenance essential
• Battery charging: Explosion risk from hydrogen gas - use well-ventilated area away from ignition sources
• Inspection pits: Trip and fall hazard, risk of flammable vapour accumulation

Workshop safety essentials

• Keep workshop tidy - avoid trailing cables and trip hazards
• Ensure adequate lighting at workstations
• Provide appropriate PPE for different tasks (eye protection, hearing protection, gloves)
• Ensure electrical equipment is maintained and tested
• Store flammable materials safely
• Have appropriate fire extinguishers available
• Ensure safe means of access to raised storage areas

Maintenance and daily checks

Many serious incidents on farms occur during maintenance or when clearing blockages. The Safe Stop procedure applies to all maintenance activities.

Before starting work each day

Conduct a walk-around check of machinery before use:

• Tyres: Check for damage, correct pressure
• Guards: All guards in place and undamaged
• Fluid levels: Oil, coolant, hydraulic fluid
• Lights and indicators: Working correctly
• Brakes: Test before moving
• Mirrors: Clean and properly adjusted
• PTO shields: In place and secure
• ROPS and seatbelt: Present and functional
• Warning decals: Visible and legible

Isolation for maintenance

Before any maintenance, cleaning, or adjustment:

1. Follow the Safe Stop procedure
2. Isolate the machine from all power sources
3. If the isolator is distant or work is not obvious, remove fuses and attach a "Danger - Do Not Start" tag
4. Release stored energy (hydraulics, pneumatics, springs)
5. Support raised components (do not rely on hydraulics alone)

Pressurised systems

Hydraulic systems, tyres, and accumulators can store dangerous amounts of energy.

• Hydraulic injection: High-pressure hydraulic fluid can penetrate skin and cause severe injury - never check for leaks with your hand
• Split-rim tyres: Can explode violently during inflation - use a cage or chain
• Accumulators: Release pressure before disconnecting

Training and competence requirements

Under PUWER, employers must ensure that all persons who use or supervise work equipment have received adequate training. This includes training on:

• Correct use of the specific equipment
• Risks that may arise from its use
• Precautions to take

Who needs training?

• All operators: Anyone who uses machinery must be trained and competent
• Supervisors: Those supervising equipment use need training too
• New workers: Particular attention for young workers and new starters
• Family members: If family members operate equipment, they need proper training just like any employee

What constitutes adequate training?

Training should be:

• Appropriate: Matched to the specific equipment and tasks
• Practical: Include hands-on operation under supervision
• Assessed: Verify competence before allowing unsupervised operation
• Recorded: Keep records of who has been trained on what equipment
• Updated: Refresher training when needed or when equipment changes

Formal training courses

For certain equipment, formal training courses are strongly recommended or effectively required:

• Telehandlers: Formal training essential - CPCS or NPORS certification commonly expected
• Forklift trucks: Formal training required
• ATVs/Quad bikes: Formal training strongly recommended (e.g., Lantra ATV courses)
• Chainsaws: Formal certification required for many tasks

Contractor machinery on farm

When contractors bring machinery onto your farm, health and safety responsibilities are shared.

Your responsibilities as the farmer

• Site information: Tell contractors about site-specific hazards (overhead lines, hidden ditches, slopes, access routes)
• Access: Ensure safe access routes for contractor vehicles
• Coordination: Coordinate activities to prevent conflicts with farm operations
• Competence check: Check contractors are competent and have appropriate insurance

Contractor responsibilities

• Ensure their equipment is safe and properly maintained
• Ensure their operators are trained and competent
• Have appropriate insurance (including employers' liability if they have employees)
• Follow site rules and instructions

Written agreements

For regular contractors or high-risk work, consider a written agreement covering:

• Who is responsible for what
• Communication arrangements
• Emergency procedures
• Insurance requirements

Second-hand machinery requirements

When buying or selling second-hand farm machinery, health and safety law still applies.

Buying second-hand machinery

Before purchasing, check:

• Guards: All guards present and in good condition
• Safety features: ROPS, seatbelt, PTO guards, safety switches
• Operator's manual: Essential for safe use and maintenance
• Maintenance records: Evidence of proper servicing
• Examination certificates: For lifting equipment (LOLER reports)
• General condition: No obvious defects affecting safety

PUWER applies: Before putting any second-hand equipment into use, you must ensure it meets PUWER requirements - suitable, maintained, guards in place, etc.

Selling second-hand machinery

If you sell work equipment (including farmer-to-farmer sales), you have legal duties under Section 6 of the Health and Safety at Work Act:

• The equipment must be safe when it leaves your control
• Including "sold as seen" on paperwork does not remove this legal duty
• You should ensure guards and safety features are present
• Provide the operator's manual if available

What to look for: common defects

• Missing or damaged PTO guards
• ROPS removed or damaged
• Seatbelts missing or inoperative
• Safety switches bypassed
• Guards modified or missing
• Hydraulic leaks
• Worn tyres or damaged rims
• Cracked welds on safety-critical components

Record keeping requirements

Proper record keeping demonstrates compliance and helps ensure machinery is properly maintained.

Records you must keep

What to record

For each machine, maintain records of:

• Identification: Make, model, serial number, year of manufacture
• Purchase documentation: Including any operator's manual and safety information
• Maintenance: Service dates, work done, who by, replacement parts
• Inspections: Pre-use checks, periodic inspections, findings, actions taken
• Thorough examinations (LOLER): Reports from competent person
• Defects: Problems identified, when, how rectified
• Modifications: Any changes to the machine, who authorised them

Record format

Records can be paper or electronic. They should be:

• Legible and durable
• Organised so information can be found quickly
• Kept securely but accessible when needed (e.g., for HSE inspectors)
• Updated promptly after work is completed