Hay Season Is Injury Season If You're Not Careful
Hay production is fundamental to Texas ranching, and the equipment you use to cut, process, and bale forage is some of the most dangerous machinery on the property. From high-speed mower blades to powerful baler pickup mechanisms, hay equipment combines many hazard types: rotating components, pinch points, crush zones, and the ever-present risk of entanglement.
Knowing the specific dangers of each piece of hay equipment and sticking to safety protocols every single time can prevent the injuries and deaths that happen every hay season across the state.
General Hay Equipment Hazards
Common Hazard Types
Entanglement points include baler pickups and augers, PTO shafts and drives, tedder tines, and rake wheels. Crush and strike hazards come from tailgate mechanisms, adjustment systems, and chain and belt drives. Movement hazards involve equipment folding and unfolding, hydraulic cylinder movement, and implements raising and lowering. Projectile risks stem from wire and twine under tension, broken components at high speed, and debris from damaged equipment.
Mower and Conditioner Safety
Rotary Mowers
- Never approach a running mower for any reason
- Keep bystanders at least 300 feet from operating mowers
- Shut down and disengage PTO before approaching
- Replace damaged or worn blades immediately
- Never operate without all guards in place
- Keep cab windows closed when mowing
Sickle Bar Mowers
Never work on the cutter bar with power connected, and keep your hands away from the sickle while transporting. Transport with the cutter bar raised and replace guards that protect the sickle during transport.
Conditioner Rolls
Shut down completely before any cleaning or adjustment, and never reach into the conditioning area. Keep guards in place over roller mechanisms, and watch for wrap accumulation that must be removed.
Baler Safety
Round Balers
Round balers are involved in numerous serious injuries and deaths each year.
- Never attempt to clear a plugged pickup while running
- Shut down, disengage PTO, remove key before ANY approach
- Stay away from the bale forming area during operation
Square Balers
Never attempt to clear a plug while the baler is running. The plunger can cycle unexpectedly, so shut down completely and keep hands away from the feeding area. Allow a complete shutdown before approaching, watch for twine under tension, and be aware of needle movement patterns.
Baler Fires
Hay balers are prone to fire due to friction from bearings, dry material around hot components, and accumulated debris near drives.
- Monitor bearing temperatures
- Carry fire extinguisher on baler or nearby
- Have water source available during baling
- Stop immediately if smoke or unusual heat is noticed
Rake and Tedder Safety
Hay Rakes
Shut down before adjustments, transport with tines raised, and watch for broken tines that can become projectiles.
Hay Tedders
Never approach a running tedder. Shut down completely before any approach, and watch for broken tines.
Hay Handling Equipment
Bale Spears and Forks
Lower spears when not carrying bales, and store equipment with spears pointed down or covered. Watch for people when operating near stacked bales.
Bale Elevators and Conveyors
Never climb on operating elevators. Use proper ladders and fall protection when stacking, and shut down before clearing jams.
Bale Wagons and Stackers
Never enter the stacking area during operation. Watch for bales that can shift and fall, and follow manufacturer procedures exactly.
Hay Storage Safety
Hay Fires
Spontaneous combustion is a real danger with hay. Bales put up too wet generate heat internally, and temperatures can reach the combustion point. Fires may smolder for days before visible flames appear.
- Monitor stack temperatures for the first 3-6 weeks
- Increase monitoring in humid conditions
- Have fire plan and extinguisher access
- Store away from buildings when possible
Stacking and Handling
Maintain stable footing because hay surfaces can be slippery. Don't stack beyond stable limits, and watch for unstable stacks.
Environmental Hazards During Hay Season
Heat and Sun Exposure
Hay season coincides with Texas summer heat.
- Stay hydrated with water always accessible
- Recognize heat illness symptoms
- Start early, break during hottest hours
- Wear light, protective clothing
- Don't work alone in extreme heat
Dust and Respiratory Hazards
Dry hay produces significant dust. Operate from enclosed cabs when possible, avoid working directly in heavy dust clouds, and be aware of allergic reactions.
Wildlife Hazards
Hay fields attract snakes seeking cover, fire ants disturbed by equipment, and bees and wasps in equipment or fields.
- Inspect equipment before reaching into spaces
- Know snake identification and response
- Have bee sting response plan if allergic
PTO Safety for Hay Equipment
Most hay equipment is PTO-driven, making PTO safety critical.
PTO-Specific Practices
- Master shield in place from tractor to implement
- Check shield condition before each use
- Never step over a running PTO
- Disengage PTO before leaving the tractor seat
- Allow PTO to stop completely before approaching
Driveline Wraps
PTO drivelines can catch and wrap clothing, hair, or limbs in an instant. Wear no loose clothing near PTO equipment, secure long hair completely, never reach over or around running drivelines, and shut down for any adjustment or lubrication.
Children and Hay Operations
Keeping Children Safe
Hay season attracts children who want to "help."
- Assign children age-appropriate tasks away from equipment
- Never allow riders on hay equipment
- Keep children well away from operating equipment
- Supervise constantly during any involvement
- Teach hazards before allowing any participation
Youth Operating Restrictions
Federal child labor laws restrict youth from operating hay balers, mowers, and related equipment, from performing certain hay handling tasks, and from working around hay equipment without supervision.
Emergency Response
For Entanglement Injuries
- Shut off all power immediately
- Call 911
- Do not attempt to reverse machinery
- Control bleeding if possible
- Keep victim calm and still
- Wait for rescue professionals
For Hay Fires
- Call fire department immediately (don't wait to see if it spreads)
- Move unaffected hay if safe to do so
- Don't attempt to fight an established fire
- Keep roads clear for fire equipment
- Protect nearby structures if possible
Bottom Line
Never approach running hay equipment. Rotating components don't forgive hesitation or mistakes, and this applies to every piece of machinery in the hay field. PTO shields must be in place on all hay equipment because this category of machinery is especially PTO-intensive. Baler pickup mechanisms kill, so shut down completely before any approach, period.
Never stand behind an operating baler during bale ejection. Hay fires are a real and recurring threat, so monitor storage temperatures and have a fire plan ready. Texas summer heat kills operators too, so manage your exposure during hay season.
Children must be kept away from operating equipment at all times. And when something goes wrong with a machine, shut down. The time lost is nothing compared to the risk.
