Every year, OSHA releases its list of the most frequently cited workplace safety violations found during federal OSHA inspections across all industries. Fall hazards, hazard communication, poor hazard communication, and unsafe equipment are among the top violations in the United States, leading to billions of dollars in preventable injuries, operational delays, and millions of dollars in fines.
OSHA’s annual list isn’t just a compliance scorecard; it’s a roadmap for better compliance and reduced liability. By understanding these common violations that plague worksites, site managers and businesses can cultivate a better culture of workplace safety, reduce accidents, and lower liability claims.
This guide breaks down each of the top OSHA safety violations, why they continue to show up, and what your company can do to eliminate them before an inspector ever arrives.
1. Fall Protection – General Requirements
Falls remain one of the leading causes of workplace fatalities. According to the National Safety Council, workplace falls accounted for over 47,000 fatalities in 2023.
Fall protection violations have held the #1 spot for over a decade, as most violations occur in construction environments where workers operate on roofs, scaffolding, platforms, or elevated surfaces without proper guardrails or harnesses.
The core of the problem stems from fall hazards present before systems are properly installed, and employers who rely on makeshift solutions rather than OSHA-compliant equipment.
How to prevent falls: Conduct pre-task safety checks, install guardrails on all elevated surfaces, ensure anchor points meet OSHA standards, and require full-body harnesses whenever workers operate at height. No employee should work unprotected, not even “for a quick task.”
2. Hazard Communication (HazCom)
OSHA’s Hazard Communication Standard requires employers to inform workers about chemical hazards through labels, SDS sheets, and training. Many citations occur because employers have chemicals on-site but no written program, outdated SDS binders, or incomplete training procedures.
In industries with frequent chemical deliveries or turnover, it’s easy for documentation to fall behind, making this violation extremely common.
How to prevent HazCom violations: Maintain an up-to-date SDS library, ensure every container is labeled correctly, train workers annually, and keep a written HazCom program accessible on-site.
3. Ladders
Ladder violations continue to rise because many job sites rely heavily on ladders for quick access. Improper ladder angles, using the wrong ladder for the job, stepping on the top rung, or climbing damaged ladders are all common issues cited during inspections.
These hazards often happen during rushed tasks, especially in construction and maintenance.
How to prevent ladder hazards: Use ladders rated for the task, inspect them daily, maintain proper height and angle, and train workers to avoid unsafe climbing practices.
4. Respiratory Protection
Respiratory hazards are widespread in construction, manufacturing, healthcare, and environmental remediation. Violations often stem from employers distributing respirators without medical evaluations, fit testing, or proper maintenance. Even when masks are available, programs often fail because they are not documented or updated.
Improper respiratory protection exposes workers to chemicals, particulates, vapors, and infectious agents.
How to prevent respiratory issues: Implement a written respiratory protection program, conduct annual fit tests, and ensure workers receive medical evaluations before respirator use.
5. Lockout/Tagout (LOTO)
Unexpected energization is one of the deadliest industrial hazards. LOTO violations occur when machinery isn’t properly shut down before maintenance, when training is lacking, or when employees bypass procedures to “save time.”
These violations frequently lead to severe injuries, including amputations.
How to prevent LOTO risks: Develop machine-specific lockout procedures, train authorized employees, provide proper lockout devices, and enforce strict compliance.
6. Powered Industrial Trucks (Forklifts)
Forklift violations occur when operators are untrained, forklifts operate with mechanical issues, or loads are handled improperly. Warehouses and retail settings are particularly prone to these hazards.
Turning corners too fast, driving with elevated loads, or operating forklifts in pedestrian-heavy areas are all red flags for inspectors.
How to prevent forklift incidents: Provide OSHA-compliant forklift training every three years, inspect equipment daily, mark pedestrian zones, and enforce safe travel speeds.
7. Fall Protection – Training Requirements
Even when fall protection systems are present, many employers fail to document or provide proper training. OSHA requires that workers know how to inspect harnesses, identify hazards, and use fall protection correctly.
A surprising number of citations stem from training gaps rather than missing equipment.
How to prevent violations: Conduct hands-on fall protection training, document all sessions, retrain workers after incidents, and verify competency before assigning elevated tasks.
8. Scaffolding
Scaffolding violations typically involve missing planking, a lack of guardrails, improper access, or untrained personnel erecting or using the system. Faulty scaffolding setups create some of the most dangerous fall hazards on a job site.
When multiple trades share scaffolding, issues arise when one team modifies the structure without notifying the others.
How to prevent scaffolding accidents: Have scaffolds erected and inspected by a competent person, ensure guardrails remain in place, and verify platforms are fully planked with proper access.
9. Eye and Face Protection
Flying particles, chemical splashes, and sparks are responsible for thousands of preventable injuries each year. Eye protection violations occur when employees remove glasses while working or when employers fail to provide PPE rated for specific tasks.
Even short exposures—such as grinding without a face shield—can result in permanent damage.
How to prevent eye and face injuries: Provide ANSI-approved safety glasses, face shields, and goggles, and enforce mandatory PPE zones.
10. Machine Guarding
Machine guarding violations arise when moving parts, belts, blades, or pinch points are exposed. Many injuries occur when guards are removed temporarily for maintenance and never replaced.
Because these hazards are often in plain sight, inspectors issue citations immediately.
How to prevent machine injuries: Ensure guards are securely installed, inspect equipment regularly, and prohibit employees from bypassing guards for speed or convenience.
Why These Violations Keep Appearing Every Year
Many OSHA violations stem from poor or missing systems that lack proper training and foresight.
Some of the most common reasons that OSHA violations persist include:
- Training that isn’t updated
- Written programs that aren’t enforced
- Equipment inspections that are inconsistent
- Workers who rush through tasks
- Safety responsibilities that are unclear
- Supervisors who assume “common knowledge”
- Documentation that is incomplete or outdated
Businesses that fully integrate safety into daily operations see fewer violations and fewer injuries.
How Employers Can Reduce OSHA Violations Before the Next Inspection
A proactive safety culture is the strongest defense against citations. Employers can drastically reduce violations by investing more into their safety training and culture.
Some recommendations include:
- Conducting regular self-audits
- Training employees frequently, not just yearly
- Keeping written programs updated and accessible
- Assigning a competent person for each high-risk area
- Addressing hazards immediately—not “when things slow down”
- Encouraging employees to report concerns without retaliation
- Documenting everything
- Daily toolbox talks that discuss recently identified issues
Hiring a third-party OSHA consultant can help you mitigate potential issues by identifying and correcting them before a formal inspection.
A strong safety culture doesn’t just protect your team; it protects your reputation, your productivity, and your bottom line. By making safety a daily priority rather than an occasional reminder, employers can stay compliant, prevent accidents, and maintain a workforce that feels supported and protected.
FAQs
What are the most common OSHA violations?
Fall protection, hazard communication, respiratory protection, ladders, and scaffolding consistently rank among the top five violations.
How much can an OSHA violation cost?
Penalties vary, but serious violations can exceed $15,000 each, while willful violations can reach over $150,000 per violation.
How often should safety training be conducted?
OSHA requires training whenever hazards change or after an incident. Best practice is quarterly refreshers plus annual certifications.
What triggers an OSHA inspection?
Inspections may occur due to employee complaints, accidents, referrals, programmed inspections, or visible hazards.
How can a business prepare for an OSHA visit?
Maintain documentation, train employees, correct hazards immediately, and conduct internal safety audits regularly.