Every year, the Occupational Safety and Health Administration (OSHA) releases a list of the most frequently cited safety violations from their inspections across the United States. These violations offer valuable insight into the recurring safety challenges many companies face, and more importantly, they highlight opportunities to improve workplace safety, avoid costly penalties, and prevent injuries or fatalities.
Whether you’re a safety manager, business owner, or operations supervisor, understanding these violations and learning how to proactively address them is essential. In this blog, we’ll explore the Top 10 OSHA violations and provide actionable tips to help your organization stay compliant and create a safer work environment.
1. Fall Protection (General Requirements – 1926.501)
Why It’s Common:
Falls are the leading cause of fatalities in construction and remain a top concern across many industries. Employers often fail to provide proper fall protection when workers are exposed to fall hazards from unprotected sides, edges, or roofs.
How to Avoid It:
- Conduct regular fall hazard assessments.
- Provide appropriate fall protection systems (guardrails, safety nets, personal fall arrest systems).
- Train workers on proper usage.
- Ensure systems are inspected and maintained regularly.
2. Hazard Communication (1910.1200)
Why It’s Common:
Many companies don’t properly label hazardous chemicals or fail to maintain up-to-date Safety Data Sheets (SDS). Training is often inconsistent or neglected.
How to Avoid It:
- Maintain a comprehensive written Hazard Communication Program.
- Label all chemical containers clearly and consistently.
- Provide employees with access to SDS for every chemical.
- Train all workers on chemical hazards and safety procedures.
3. Respiratory Protection (1910.134)
Why It’s Common:
Employers sometimes provide respirators without proper medical evaluations, fit testing, or training. Respiratory programs are often incomplete or not enforced.
How to Avoid It:
- Conduct a hazard assessment to determine respiratory risks.
- Implement a written Respiratory Protection Program.
- Ensure proper medical evaluations and annual fit testing.
- Train employees on use, cleaning, and limitations of respirators.
4. Ladders (1926.1053)
Why It’s Common:
Improper ladder usage is a frequent issue, particularly in construction. This includes using damaged ladders, improper placement, or using the top step.
How to Avoid It:
- Inspect ladders before every use.
- Ensure ladders are rated for the task and height.
- Train workers on proper ladder safety.
- Prohibit the use of damaged or makeshift ladders.
5. Scaffolding (1926.451)
Why It’s Common:
Scaffolding violations often result from improper assembly, lack of fall protection, or inadequate access.
How to Avoid It:
- Have a competent person design and inspect scaffolding.
- Use guardrails, midrails, and toeboards.
- Provide safe access via ladders or stairs.
- Train workers on scaffolding safety and fall protection.
6. Lockout/Tagout (Control of Hazardous Energy – 1910.147)
Why It’s Common:
Failing to control hazardous energy during maintenance and repair tasks leads to severe injuries and fatalities. Inadequate procedures and training are frequent issues.
How to Avoid It:
- Develop written lockout/tagout procedures for each machine.
- Provide lockout/tagout kits and ensure proper usage.
- Train authorized and affected employees.
- Audit your program annually to ensure compliance.
7. Powered Industrial Trucks (1910.178)
Why It’s Common:
Forklifts and similar vehicles are commonly involved in workplace accidents. Violations typically involve inadequate training or improper operation.
How to Avoid It:
- Certify operators through OSHA-compliant training.
- Conduct daily inspections of equipment.
- Enforce safe operation rules (speed limits, loads, clear paths).
- Reevaluate and retrain operators every three years.
8. Fall Protection – Training Requirements (1926.503)
Why It’s Common:
Even when fall protection systems are provided, many employers fail to properly train employees on their use.
How to Avoid It:
- Develop a comprehensive fall protection training program.
- Ensure training includes recognizing fall hazards and proper equipment use.
- Keep written records of all training.
- Refresh training regularly, especially after any incident or near miss.
9. Personal Protective and Lifesaving Equipment – Eye and Face Protection (1926.102)
Why It’s Common:
Many employers overlook eye and face hazards such as flying debris, chemical splashes, or radiation. Lack of PPE or failure to enforce its use is a typical issue.
How to Avoid It:
- Assess job tasks for eye and face hazards.
- Provide appropriate PPE (safety glasses, goggles, face shields).
- Train employees on proper use and care of PPE.
- Replace damaged or expired protective equipment.
10. Machine Guarding (1910.212)
Why It’s Common:
Unprotected machinery poses serious hazards like amputations. Many violations occur due to missing or bypassed guards on moving parts.
How to Avoid It:
- Install guards on all hazardous moving parts (belts, gears, blades).
- Conduct regular inspections of machinery.
- Train employees on the importance of guarding and not bypassing safety features.
- Ensure only qualified personnel conduct repairs and maintenance.
The Cost of Non-Compliance
Beyond the physical risks to workers, OSHA violations carry significant financial penalties. As of 2025, the maximum penalty for a serious violation is over $16,000 per incident, and willful or repeated violations can exceed $161,000 per violation.
Repeat violations or a history of non-compliance can also damage your company’s reputation, lead to project delays, or result in loss of business opportunities, particularly in industries that require strict safety protocols like construction, manufacturing, logistics, and energy.
How Your Company Can Stay Ahead
Avoiding OSHA violations requires a proactive and ongoing approach to safety. Here’s how you can stay ahead:
- Conduct Regular Safety Audits: Identify risks before OSHA does. A third-party consultant can offer an objective perspective.
- Stay Current with Regulations: OSHA standards evolve. Subscribe to updates and ensure your team remains informed.
- Invest in Training: Don’t just tick the box, develop engaging, hands-on training that workers actually retain.
- Encourage a Safety Culture: Empower employees to speak up about hazards and take ownership of safety practices.
Final Thoughts
Understanding and addressing the most common OSHA violations is not just about avoiding fines, it’s about building a safer, more productive workplace where employees thrive. At Safety Pro Specialists , LLC, we help companies across the U.S. stay compliant, reduce risk, and foster a safety-first culture.
If you’re unsure where your business stands, contact Safety Pro Specialists , LLC today for a professional safety assessment, tailored training, or full safety program development. Your people, and your bottom line, will thank you.