Farm machinery safety

If you employ people on a farm, or work on one as a self-employed person, PUWER requires every machine used to be suitable for the job, maintained, inspected and safely guarded, and LOLER adds thorough examinations for lifting equipment such as telehandlers and loaders. You must assess the risks of each machine, train everyone who uses it, and keep children and young workers within the legal age limits.

Transport and machinery cause most deaths and serious injuries on farms, to workers, family members, contractors and visitors alike. HSE investigates farm deaths and can prosecute, with unlimited fines. Most of these accidents are preventable through 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

Tractor three-point linkages are not considered lifting equipment under LOLER when used to lift implements designed to be operated on a tractor. However, if you use equipment to lift loads or people, LOLER applies.

Never lift people in:

• Telehandler buckets
• Forklift forks
• Potato boxes or other containers
• Front-end loader buckets

People should only be lifted using equipment specifically designed for that purpose, such as a MEWP (mobile elevating work platform) or purpose-built lifting cage with proper certification.

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, and whether they are trained, competent and old enough
• its hazards, such as moving parts, entanglement, crushing, shearing, cutting and ejected material
• whether guards are in place and being used
• whether it is maintained: records, inspection intervals and known defects
• what could go wrong, such as blockages, breakdowns, slopes and uneven ground
• who else could be harmed, such as family members, visitors, contractors and 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, which crushes or traps the driver
2. being run over, when a driver or bystander is struck by a 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.

The legal requirements are:

• 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.

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 whole length of the shaft including universal joints
• undamaged, with no cracks, holes or missing sections
• properly fitted, so they rotate freely around the shaft
• secured at both ends so they do not rotate with the shaft

Guard components required:

• the tractor PTO shield, the "U" guard covering the tractor PTO stub
• the machine input shield, the "O" guard on the machine side
• the 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:

• being drawn into the cutter bar and reel
• drawing-in and entanglement by augers in the header and grain tank
• the high-speed rotating knives of the straw chopper
• fire from dust, chaff and hot components
• falls when climbing on the machine for maintenance or to check the crop
• running people over, because of large blind spots

Safe operating procedures

• Never try 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 build-up around the engine daily.
• Watch for overhead power lines, which the unloading auger and the header in transport position can touch.
• Keep three points of contact when climbing on the machine.
• Keep bystanders away from a working combine.

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
• running people over, because of poor visibility when reversing or carrying large loads
• loads becoming unstable or falling from height
• people being crushed between the 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: lift capacity falls as the boom extends.
• Keep loads close to the ground when travelling.
• Deploy stabilisers, where fitted, for heavy or high lifts.
• Look all around and sound the horn before moving off.
• Travel in reverse if the load blocks your forward view.
• Avoid slopes, where telehandlers are particularly unstable.
• Use only attachments the manufacturer approves.

Lifting equipment examination

Telehandlers used for lifting require thorough examination under LOLER:

• every 12 months for lifting equipment
• every 6 months for lifting accessories such as slings, chains and 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 deaths in the UK.
• Get proper training in the "active riding" techniques quad bikes need to stay stable.
• Never carry passengers on a sit-astride ATV: the long seat is for shifting your weight. Carrying children as passengers is illegal.
• Do not overload racks; excessive or badly distributed loads cause instability.
• Check tyre pressures regularly, as even small differences affect stability.
• Do not push the machine beyond its 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 the correct wheel, set tool rests close to it and wear eye protection
• welding, which risks arc eye for bystanders and fire, and needs fume extraction
• vehicle hoists and jacks, which must be rated for the load and maintained
• compressors and pressure equipment, which can burst if not maintained
• battery charging, which gives off explosive hydrogen, so charge in a well-ventilated area away from ignition sources
• inspection pits, which are a fall hazard and can collect flammable vapour

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 for damage and correct pressure
• all guards and PTO shields in place, secure and undamaged
• oil, coolant and hydraulic fluid levels
• lights and indicators working
• brakes, tested before moving
• mirrors clean and adjusted
• ROPS and seatbelt present and working
• 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.

• High-pressure hydraulic fluid can penetrate skin and cause severe injury, so never check for leaks with your hand.
• Split-rim tyres can explode violently during inflation, so use a cage or chain.
• Release the pressure in accumulators before disconnecting them.

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?

Everyone who uses machinery must be trained and competent, and so must the people who supervise them. Pay particular attention to young workers and new starters. Family members who operate equipment need the same training as any employee.

What constitutes adequate training?

Training should be:

• matched to the specific equipment and tasks
• practical, with hands-on operation under supervision
• assessed, so you confirm competence before allowing unsupervised use
• recorded, showing who has been trained on what
• refreshed when needed or when equipment changes

Formal training courses

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

• telehandlers, where CPCS or NPORS certification is commonly expected
• forklift trucks
• ATVs and quad bikes, for example Lantra ATV courses
• chainsaws, where certification is 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

• Tell contractors about site hazards such as overhead lines, hidden ditches, slopes and access routes.
• Provide safe access routes for their vehicles.
• Coordinate their work with farm operations to avoid conflicts.
• Check they 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:

• all guards are present and in good condition
• safety features such as ROPS, seatbelt, PTO guards and safety switches are fitted
• the operator's manual comes with it
• there are maintenance records showing proper servicing
• lifting equipment has its LOLER examination reports
• there are no obvious defects affecting safety

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

Good practice is to keep maintenance records for 5 to 10 years or the life of the machine, training records for the length of employment plus 6 years, and earlier versions of risk assessments for 3 to 5 years.

What to record

For each machine, maintain records of:

• make, model, serial number and year of manufacture
• purchase documents, including the operator's manual and safety information
• servicing: dates, work done, who did it and parts replaced
• pre-use checks and periodic inspections, with findings and actions taken
• LOLER thorough examination reports
• defects found, when, and how they were put right
• modifications and 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