Top 5 Hazards in Cotton Farming

Cotton farming comes with its fair share of risks. From large machinery and agricultural chemicals to powerlines, falls, heat and long days in the sun, there are plenty of hazards to keep an eye on.

And these risks can have serious consequences. According to the Cotton Research and Development Corporation (CRDC), 46 people lost their lives while working in Australia’s cotton and grains industries between 2019 and 2025. The estimated economic cost of these fatalities was $125.8 million, with workers’ compensation claims adding another $64.3 million between 2021-22 and 2023-24.

Knowing where the main risks are is a good place to start. Here are five of the key hazards cotton farmers and their workers need to look out for.

1. Machinery and equipment
2. Chemicals and cotton dust
3. Slips, trips and falls
4. Electricity and overhead powerlines
5. Heat, sun and other environmental hazards

Machinery and Equipment

It would be hard to run a cotton farm without machinery. Tractors, cotton pickers, planting equipment and other machines help get the job done, but they can also create serious risks if something goes wrong.

Some of the common machinery hazards include:

• Entanglement with belts, pulleys, gears, shafts and other moving parts
• Crush injuries when clearing blockages or carrying out maintenance
• Collisions between machinery, vehicles, workers or other objects
• Falls when getting on or off machinery
• Unexpected movement while machinery is being cleaned, repaired or serviced

Making sure workers know how to safely operate each machine is an important first step. Machinery should also be regularly checked and maintained, with guards kept in place around dangerous moving parts.

If a blockage needs clearing or machinery needs to be cleaned or repaired, make sure it is stopped and isolated before work starts.

With large machinery such as cotton pickers, it's also worth considering things like restricted visibility, elevated components and moving parts.

Chemicals and Cotton Dust

Chemicals are a normal part of many cotton-growing operations. Pesticides, herbicides, fertilisers and other agricultural chemicals can all create risks if they're not handled, stored or used correctly.

Workers can be exposed through their skin, by breathing in chemicals or through accidental contact.

Cotton dust can also be a concern, particularly during harvesting, cleaning and machinery maintenance. Breathing in dust and other airborne particles can irritate the eyes, nose, throat and airways and may make existing respiratory problems worse.

Some simple ways to reduce these risks include:

• Follow the instructions on the product label
• Make sure workers are trained before handling chemicals
• Use the right personal protective equipment (PPE)
• Store chemicals safely
• Keep people away from areas being treated
• Keep machinery and ventilation systems well maintained
• Use suitable respiratory protection when there is a risk of breathing in dust or other airborne contaminants

If machinery has a filtered cabin, make sure the filtration system is maintained and working properly.

Slips, Trips and Falls

A fall might not sound like one of the biggest risks on a cotton farm, but they can happen pretty easily.

Uneven ground, mud, wet surfaces, cluttered work areas and damaged steps can all create trip and fall hazards. Workers can also be at risk when getting on and off machinery or carrying out maintenance.

A few simple steps can help:

• Keep work areas and accessways clear
• Keep steps, ladders, handrails and handles in good condition
• Use slip-resistant surfaces where needed
• Make sure there is enough lighting, especially when working at night
• Wear suitable footwear
• Keep three points of contact when climbing on or off machinery
• Don't jump off machinery

Take extra care around cotton pickers and other large machinery, particularly when surfaces are wet, dusty or difficult to see.

Electricity and Overhead Powerlines

Overhead powerlines are easy to overlook, but they can be extremely dangerous when you're operating large machinery.

Cotton pickers, tractors, irrigation equipment and other machinery can come close to powerlines during everyday farm work. Raising a basket or other part of a machine can also reduce the clearance between the machinery and the powerline.

Coming into contact with a powerline can cause serious injury or death.

To reduce the risk:

• Know where overhead powerlines are located
• Mark powerlines and other hazards on your farm map
• Plan safe routes for machinery
• Know and follow the required exclusion zones
• Make sure workers understand the risks before operating machinery near powerlines
• Check the height and clearance of machinery before moving it near powerlines

A good farm hazard map can help workers quickly see where powerlines, dams, structures and other hazards are located.

Heat, Sun and Other Environmental Hazards

Cotton workers can spend long hours outside, often in hot and sunny conditions. Heat, UV exposure, dust and noise can all affect workers throughout the day.

Heat stress

Working hard in hot weather can lead to dehydration, heat exhaustion and heat stroke.

To help manage the risk:

• Make sure workers have plenty of drinking water
• Schedule regular breaks
• Provide shade or a cool area where possible
• Plan heavy work around the hottest part of the day
• Keep an eye out for signs of heat-related illness
• Check the weather before planning work

Sun exposure

Long periods in the sun increase the risk of skin cancer and can also affect the eyes.

Workers should have access to sunscreen, sunglasses, protective clothing and a broad-brimmed hat. It's also worth considering how work can be planned to reduce unnecessary exposure during the hottest parts of the day.

Noise

Cotton pickers, tractors and other machinery can be loud, particularly when workers are around them for long periods.

Too much noise over time can cause permanent hearing damage. It can also make it harder to hear warnings or communicate with other workers.

Where noise can't be reduced enough through other controls, workers should use suitable hearing protection such as earmuffs or earplugs.

Managing Cotton Farm Safety

Knowing the hazards is only part of the job. Once you've identified a risk, you need to work out how to control it and make sure those controls are actually being used.

A practical approach to cotton farm safety includes:

• Identifying hazards around the farm
• Assessing the risks they create
• Putting controls in place
• Training and supervising workers
• Keeping machinery and equipment maintained
• Recording hazards, incidents and actions
• Checking that controls are still working
• Reviewing safety procedures when things change

Keeping your safety information, training records, machinery checks, risk assessments and actions in one place can also make it easier to stay on top of what's happening across the farm.

Topics: Safety for Cotton Farming

FAQ

What are the main hazards in cotton farming?

The main hazards in cotton farming include machinery and equipment, agricultural chemicals and cotton dust, slips and falls, electricity and overhead powerlines, and environmental hazards such as heat, UV radiation and noise.

What are the risks of cotton farm machinery?

Cotton farm machinery can create risks such as entanglement, crushing, collisions, falls and unexpected movement. Regular maintenance, guarding, training and safe operating procedures can help reduce these risks.

What are the health risks of cotton dust?

Cotton dust and other airborne particles can irritate the eyes, nose, throat and airways. Workers who are regularly exposed may also be at greater risk of respiratory problems.

How can cotton farmers reduce workplace hazards?

Cotton farmers can reduce workplace hazards by identifying risks, putting suitable controls in place, maintaining machinery, training workers and regularly checking that safety procedures are working.

Why are overhead powerlines dangerous on cotton farms?

Large farm machinery can come into contact with overhead powerlines, particularly when raised components are close to the lines. Contact with electricity can cause serious injury or death, so workers need to know where powerlines are located and understand the required exclusion zones.

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