Understanding the Job:In our line of work, dealing with hay bales is a common task, and it's crucial to grasp the potential risks involved, especially considering that some hay bales can weigh up to 800kg.

What does it Mean to Work with Hay Bales?Hay bales come in various forms, such as small rectangular, large rectangular, or large round, made from compressed grass, lucerne, straw, or other plant materials. These bales are tightly bound or compressed, including the wrapped round silage bales. The baling process takes place in the fields or paddocks where the hay is grown and dried. Primarily, hay is used for livestock feed, and it also serves as bedding for animals.

After the baling process, the hay is typically moved from the paddock to storage, stacked, and later transported or used. Working with hay bales involves the lifting and moving of these bales, typically employing vehicles and machinery.

Risks Associated with Working with Hay Bales:Working with hay bales presents numerous hazards and risks that demand attention and caution. These include:

• Injuries such as broken bones, fractures, and head injuries from falls off bale stacks, vehicles, and machinery used for transport or stacking, as well as runover accidents.
• Crush injuries or the risk of fatality from falling or collapsing bales, considering that well-packed large bales can weigh up to 800kg, and from potential contact with moving vehicles and machinery.
• Electrocution risks from accidental contact with overhead powerlines.
• Trips and falls resulting from loose bale string.
• Pinch, entanglement, and entrapment injuries, ranging from minor grazes to severe consequences like amputations or even fatalities, caused by interactions with bale handling machinery.
• Burns due to contact with haystack fires.
• Manual handling injuries like sore backs, pulled muscles, and strains incurred during the lifting and carrying of bales.
• Respiratory diseases and infections arising from prolonged exposure to dust.

In our work, prioritizing safety is key, and every worker should remain vigilant to minimize these risks associated with handling hay bales.

Photograph 1: Hay bales can fall from a truck during unloading.

Photograph 2: Bales transported on their sides or inadequately secured can move while being transported.

In our line of work, where hay bales are part of the job, it's crucial for both workers and managers to collaborate in minimizing the associated risks.

For Workers:As a worker, your responsibilities include:

• Prioritizing your health and safety, as well as that of your colleagues.
• Cooperating with management to meet health and safety requirements and actively contributing to risk reduction efforts.

For Businesses:If you're an employer or business owner, you have legal obligations outlined in the Work Health and Safety Act 2011. Ensuring the health and safety of every worker and visitor is paramount. The following four-step process aids businesses in meeting legal obligations under work health and safety (WHS) laws.

Four Steps to Manage Risk:

Step 1. Identify the Risk:To manage the risk of harm to workers handling hay bales, the first step involves identifying hazards related to the work tasks and environment. This can be achieved by:

• Inspecting the farm and work processes.
• Evaluating the suitability and maintenance of bale handling equipment.
• Verifying that workers are adequately trained for assigned tasks.

Engage in conversations with workers to gauge their awareness of potential hazards and gather insights on improving safety processes. Regularly review records, including workers’ compensation claims and incidents, to identify trends and implement preventive measures.

Step 2. Assess the Risk:The next step is to assess the level of risk associated with each identified hazard. This assessment considers the seriousness of potential harm and the likelihood of its occurrence. Utilize the provided risk assessment template to guide this process and document your assessments.

Step 3. Control the Risk:The law mandates the elimination or minimization of risks as much as possible. The hierarchy of controls offers guidance on selecting measures that effectively mitigate risks. This may involve a single control measure or a combination of multiple controls. Some general controls applicable to all tasks with hay bales include ensuring proper worker training, using well-maintained equipment, and working on flat and even surfaces whenever feasible.

Specific controls for tasks like dealing with falling or collapsing hay bales involve adhering to industry guidelines, utilizing appropriate lashing techniques, and employing equipment designed for hay bale handling.

Regularly reviewing and adjusting control measures is vital to maintaining a work environment free from risks to health and safety. This approach aligns with work health and safety laws, necessitating reviews in response to incidents, new risks, or worker feedback.

Photograph 3: Bale spikes.

Photograph 4: Big bales grabs attached to a telehandler.

Photograph 5: Front end loader with large square bale.

A tractor without FOPS puts workers at risk of injury from a falling hay bale.

Following are examples of the clearances that people, machinery, and plant must maintain from powerlines.

Falling from heights:

• Use mechanical equipment or aids to load or remove bales, and to assist with placing or removing lashings, tarps, or other securing devices to stop the need for workers to climb on the stack.
• Ensure there’s a safe way for workers to move up onto and down from work positions that are above ground level.
• Give workers a way to get up onto and down from truck or trailer beds that doesn’t need them to jump from heights.

Keeping bystanders safe:

• Set up an exclusion zone to keep bystanders (including truck drivers) from the loading zone.
• Ensure no-one is on the opposite side of the truck or trailer during loading or unloading.
• Nominate a spotter (who has communication to the mobile plant operator) to prevent people entering the loading zone area.
• Ensure driving routes are well defined.
• Never transport workers on loads or loading equipment.
• Use signs or barriers to keep members of the public or anyone not involved with the loading or unloading operation away.

Step 4. Review risk controls

You should regularly review your control measures. Don’t wait for something to go wrong. If necessary, change or adjust your approach. The aim is to maintain a work environment that is without risks to health and safety.

Work health and safety laws require you to review controls:

• when you become aware a control measure is not working effectively
• before a change that might introduce a new risk
• when you find a new hazard or risk
• when your workers tell you that a review is needed
• after a health and safety representative requests a review.