On a crisp, fall evening, the sun was just setting. The harvest was in full swing. The corn was coming off at 19 percent moisture. The grain bins were filling fast. The wet bin was full, and the dryer ran at capacity. The farmer and farmhands were trying to quickly ship out dry corn by the truckload that was contracted with the terminal. Suddenly, while the farmer and the farmhands were in the process of loading the grain trailer, the grain stopped coming out of the tube. The farmer didn’t know why this problem happened. This experienced, lifelong farmer went through the normal reasons that might cause the tube to clog, but he needed that grain moved in a hurry to make room for the next wagon load out of the field.
He tried to restart the auger, knowing that the bin should be 75 percent full and unloading quickly. A small amount of grain began to run out but then quit again. Doing what most farmers do on a semiregular basis, the farmer went to top of the bin to see what the issue might be. He noticed a small funnel where corn had been running out. Even though the corn still was trickling out, he entered the bin: As most farmers do, he saw little danger in entering bins, as he did many times without any issues. After entering, he walked through the grain to the middle, planning to use a rod to probe the grain to attempt to get grain flowing. He then felt himself sinking. While attempting to get out, he twisted and turned, but with each movement, he only sank lower.
His family and the other farmhands realized that there were problems and notified 9-1-1. Dispatch sounded the tones, and first responders were advised and dispatched.
This is where it starts for rescue crews. From the time of dispatch, the plan of attack is devised. Many prerescue tasks must be done—every situation presents different problems and solutions—but below, the typical plan of attack and a newer method are discussed.
Traditional grain bin rescue
The current way that’s taught to rescue a person from a grain bin uses grain rescue tubes. This method is good when you can see your victim. However, if you can’t see the victim, you must use something to probe through the grain to attempt to locate the individual. Once you find the victim, the tube comes into play.
By placing the tube around the victim, you give the person additional protection from the compression of the grain. In effect, it’s like taking a 30,000-bushel (bu) grain bin and turning it into a 15-bu bin directly surrounding the victim. Making a smaller bin allows you to remove the grain from around the victim much more quickly.
The rescue tube gives you the ability to perform the rescue by moving smaller amounts of grain from around the victim. Use of the trub also allows you to loosen up the victim, so the person can be moved out.
Rescuers must keep in mind that the grain has a considerable amount of suction, and by trying to force out the victim, members can injure the individual. This grain can be removed in multiple ways: buckets, cans or even a small auger that’s operated by a drill, whichever is available and most efficient for the situation.
The alternative: cut the bin
The new method of rescuing an individual from a grain bin is much quicker than the traditional method and probably a better option when the victim can’t be located quickly. Grain is removed systematically by cutting the bin. There are specific reasons for how, where and why cuts are made.
The farmer who is mentioned above went into an 18-ring bin that was 36 feet in diameter, with corn at 14 rings. He fell through and was unable to be located. Each ring is estimated at 40 inches. A rough estimate of how much grain is in each ring must be made. A quick formula to use is: bushels = 0.628 x 36 x 36 x 3.333. This means that there is approximately 2,700 bu per ring. This will be important below when cutting the bin is explained.
Knowing the average height of a male individual is 5 foot, 8 inches is necessary for your calculations. Two rings are 80 inches high, which is a little more than 6½ feet, so, in the case that’s described, the rescue starts three rings below the level of the grain that’s in the bin. This is where the first cuts—three evenly spaced cuts around the bin—are made. The cuts can be keystone or triangle. The effort is to attempt to release the top two rings of grain—approximately 5,000 bu—onto the ground.
Let’s try to wrap our head around what 5,000 bu looks like. Most people have seen a semitrailer truck hauling a grain trailer. Each trailer carries about 1,000 bu. So, picture five full trailer loads of grain dumped on the ground.
When you make your cuts and release the grain, you must remember not to cut through an upright bin stiffener and to attempt to avoid cutting through bolt joints.
A spotter should be placed at the top of the bin to see if/when the victim appears. If the victim becomes visible, you should attempt to get some type of rope and harness or safety system on the individual in an effort to stabilize the person.
People often are concerned about how to cut these holes because of concern of a dust explosion. Yes, above the grain level at the top of the bin, dust and atmospheric issues could cause an explosion from sparks that come off of the cutting equipment. However, if you cut into the grain—rather than in the air that’s above the top level of the grain—you shouldn’t be cutting into an explosive atmosphere.
(Note: The tool to use to cut is up to the people who are cutting the bin. We have found that a reciprocating saw is the most manageable saw, but a plasma cutter works well when the crew is well trained with it.)
The bottom line of the process is to manage the release of grain. By starting high, you won’t pull your victim deeper. Furthermore, when the bin is opened low, you only get small amounts of grain out before you must remove grain that’s on the ground, which wastes precious time.
By starting high, you can keep moving down two rings at a time and rotating your cuts. This allows the bin to retain structural strength and allows the grain to flow out without having to move grain.
Flexibility for plan of attack
You could be involved in 100 grain bin rescues, and each one will be different. There could be rain, snow or blazing heat. Your victim might have been missing for hours or five minutes. Maybe someone saw the individual go in or the person was missed after a significant passage of time.
Always assume that the victim is alive. Know where the closest grain rescue tube is located and request it immediately.
Remain fluid in your plan of attack, be willing to listen to suggestions, and keep up on the latest in equipment and procedural developments.
