Replacing unsafe pry-bar methods with railcar gate openers eliminates injuries and improves efficiency in railcar loading. Here’s how we improved operator safety, standardized procedures across multiple facilities, and enhanced productivity in a demand grain-handling agricultural environment.
About the Project
This job story highlights how a simple mechanical improvement can eliminate long-standing safety risks in bulk-material handling.
At a large agricultural cooperative in the Upper Midwest, operators were experiencing frequent injuries while using heavy pry bars to close railcar gravity gates during grain-loading operations. Concerned about both worker safety and efficiency, the Environmental Health & Safety (EHS) team sought an economical, standardized solution using safer railcar gate openers that could be implemented across multiple facilities.
The Challenge
Before railcars could be filled, their gravity gates had to be securely closed. Operators traditionally used six-foot pry bars inserted into the small outer holes of each capstan barrel to force the gates shut. This manual process created several issues:
Safety Hazards
- Pry bars often slipped from the barrel, striking operators or causing falls.
- Operators experienced strains and impacts to hands, wrists, shoulders, and backs
Inefficiency
- Gravity gate closing was slow, awkward, and physically demanding.
- Operators had to reposition the pry bar in the capstan barrel multiple times, and then reapply manual force to fully seat each gate.
Inconsistency
- Each site used different improvised tools rather than a standardized railcar gate opener
- Techniques varied widely, creating uneven performance and no uniform safety practice.
Without a reliable railcar gate opener, operators depended on improvised tools that created unnecessary risk. The cooperative recognized that continuing this approach exposed personnel to preventable injuries and slowed down railcar loading operations. Eliminating pry-bar use became a top safety initiative across its locations.
How We Solved It
AIRMATIC proposed the WORKMASTER GO-M04 Manual Ratchet Gate Opener, a compact, bi-directional manual railcar gate opener with a powerful mechanical advantage designed to safely and efficiently close railcar gravity gates.
Unlike pry bars that rely on leverage against the outer holes of the capstan barrel, the GO-M04 engages directly with the square drive opening at the barrel’s center. This secure male-to-female connection prevents slippage, maximizes torque transfer, and allows smooth, no-torque-reaction ratcheting in both directions. Despite being only 36 inches long—half the length of a typical pry bar—the GO-M04 delivers equivalent closing force with far less strain on the operator.
AIRMATIC supplied multiple GO-M04 assemblies and provided instructions for proper use and safe handling, enabling the cooperative to standardize the procedure at each of its shuttle-loading sites.
The AIRMATIC Impact
By replacing pry bars with the WORKMASTER GO-M04, the agricultural cooperative eliminated a major source of injury and improved the efficiency of its railcar-loading operations. The tools have performed flawlessly since installation, requiring no maintenance or replacement.
This case demonstrates how a straightforward mechanical solution can significantly improve operator safety, standardize procedures across multiple facilities, and enhance overall productivity in demanding grain-handling environments.
If opening and closing railcar gates is creating safety risks or slowing down your grain-loading workflow, AIRMATIC can help identify the right railcar gate opener for your site. Contact us at 215-333-5600 or infocenter@airmatic.com.
Railcar Gate Openers & Accessories
AIRMATIC offers a full range of hopper car gate openers and accessories for railcar unloading operations. Whether you're dealing with difficult gates, limited utilities, or changing site conditions, our equipment is built to support safer, faster, and more reliable unloading.
