CSP/Equipment/TBT-CSP-014

Silos and Hoppers

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Silos and Hoppers

Toolbox Talk Record

Ref: TBT-CSP-014  |  Issue: 1  |  Date: March 2026
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What?

  • Silos and hoppers are enclosed vessels used to store bulk materials such as cement, aggregate, or grain.
  • Entry into silos and hoppers is classified as confined space work under the Confined Spaces Regulations 1997.
  • Engulfment in stored material is the single greatest cause of death inside silos and hoppers.
  • Bridged material can collapse suddenly when disturbed, burying workers in seconds.
  • Toxic or oxygen-depleted atmospheres can develop from decomposing materials or chemical reactions.
  • Mechanical hazards include augers, discharge gates, and rotating feeders at the base.
  • Work on or inside silos often combines working at height with confined space risks.
  • Several fatalities occur in the UK each year involving silos and hoppers on construction and industrial sites.
  • The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) may also apply to dust-laden silos.
  • A safe system of work must be in place before anyone enters, works on, or works near a silo or hopper.

Why?

Prevent fatalitiesEngulfment in bulk material is nearly always fatal. Strict controls prevent workers being trapped or buried.
Legal complianceThe Confined Spaces Regulations 1997 require a risk assessment and permit before any entry into a silo or hopper.
Protect workers' healthDust inhalation, oxygen depletion, and toxic gases inside silos can cause serious illness or death within minutes.
Do Don't
  • Treat every silo and hopper as a confined space requiring a permit to enter
  • Isolate all mechanical and electrical equipment before entry using LOTO procedures
  • Test the atmosphere for oxygen, flammable gases, and toxic substances before entry
  • Ensure a trained rescue team and equipment are on standby throughout the work
  • Use a full body harness attached to a tripod and winch for vertical entry
  • Confirm stored material has been fully discharged and cannot flow back in
  • Maintain continuous communication between entrant and top man at all times
  • Ventilate the space mechanically before and during any entry or work
  • Brief all personnel on the emergency rescue plan before work begins
  • Monitor the atmosphere continuously with calibrated gas detection equipment
  • DON'T enter any silo or hopper without a valid confined space entry permit
  • DON'T assume the atmosphere is safe because the silo appears empty
  • DON'T stand on bridged material — it can collapse without warning
  • DON'T work inside while discharge equipment is still energised or operational
  • DON'T enter without a rescue plan, trained standby team, and rescue equipment
  • DON'T use the silo ladder for access without a full fall arrest system
  • DON'T ignore alarms from gas detection equipment — evacuate immediately
  • DON'T allow unauthorised personnel near open silo hatches or access points
  • DON'T use tools that could create sparks in a dust-laden atmosphere
  • DON'T poke or prod bridged material from inside the silo to free blockages

See also: Confined Space Entry Procedures | Atmospheric Monitoring and Gas Testing
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