What are the Most Common OSHA Violations, and How Can Companies Avoid Them?

Workplace safety is not just a matter of compliance; it’s about protecting the people who keep your company running every day. The Occupational Safety and Health Administration (OSHA) sets and enforces standards to ensure safe working conditions for employees across industries, and employers are responsible for maintaining safe workplaces that comply with OSHA standards. Despite these standards, however, thousands of violations are cited every year. Many of them are the same issues, repeated across worksites and industries, and sometimes even across the same organization if procedures are not updated or put in place to stop recurring violations.

Fortunately, most violations can be avoided. All it takes is an organization being proactive and working to keep employees safe. This process involves organizations looking at the number of incidents occurring and creating new policies and procedures to prevent repeat incidents. For instance, if hand injuries are a problem, a company might need to put in place procedures for proper hand protection, such as gloves. Understanding the most common OSHA violations and how to prevent them can help companies reduce risks, protect their employees, and avoid costly fines.

Every workplace has hazards, but employers have a legal and moral responsibility to address those hazards, establish safety standards in their workplace, and ensure employees are properly equipped to handle the hazard. When employers fail to do this, that’s when OSHA violations occur. The consequences can be serious, and can include:

• Injuries/Fatalities: Noncompliance increases the likelihood of accidents, injuries, and even fatalities. This not only leads to a diminished workforce, but employees who remain will have lower morale if they feel that their safety isn’t being taken seriously.
• Financial Loss: Unsafe conditions and accidents can halt production, leading to costly downtime, and OSHA penalties can range from thousands to hundreds of thousands of dollars, depending on the severity and frequency of violations. Beyond fines, companies often face lawsuits, workers’ compensation claims, and higher insurance premiums. Additionally, legal trouble can lead to the company having to be shut down due to violations.
• Poor Reputation: A strong safety record builds trust with employees and clients. On the other hand, repeated violations can damage a company’s reputation and make it harder to attract and retain skilled workers. This inability to hire and keep employees ties in directly with financial loss, as the company will incur high costs from constant onboarding and employee turnover, and jobs can take longer to get done as training takes precedence.

For these reasons, staying ahead of OSHA violations is absolutely necessary for the success of any organization.

Each year, OSHA publishes a list of the top 10 most frequently cited workplace safety violations. While the exact ranking changes slightly from year to year, the same types of issues consistently appear. For this section, we have taken information from OSHA’s Top 10 Most Frequently Cited Standards for Fiscal Year 2024 (Oct. 1, 2023, to Sept. 30, 2024). These include:

1. Fall Protection (General Requirements): Falls are the leading cause of fatalities in the construction industry. Violations typically involve missing guardrails, unsafe scaffolds, or failure to provide fall arrest systems when workers are at height. During the fiscal year of 2024, there were 6,827 violations, which shows just how important it is for companies to ensure training and personal protective equipment is being provided to employees.
2. Hazard Communication: Chemical safety is a recurring challenge. Violations occur when employers fail to properly label hazardous chemicals, maintain Safety Data Sheets (SDS), or train employees on how to handle dangerous substances.
3. Ladders: Improper use, damaged equipment, or ladders that don’t meet safety standards are common violations. Many injuries happen because workers stand on the top step or use ladders that are not the right height for the job.
4. Respiratory Protection: When workers are exposed to airborne hazards—such as dust, chemicals, or fumes—OSHA requires employers to provide respiratory protection. Violations include missing or inadequate respirator programs, lack of fit testing, or failing to train employees on proper use.
5. Control of Hazardous Energy (Lockout/Tagout): Hazardous energy control is vital during equipment maintenance. Violations happen when companies fail to lock out machines before servicing, putting workers at risk of electrocution, crushing, or amputation.
6. Powered Industrial Trucks: Forklift violations often involve inadequate operator training, poor maintenance, or unsafe operation. These violations lead to serious accidents, including collisions, tip-overs, and struck-by incidents.
7. Fall Protection (Training Requirements): Even when fall protection systems are in place, employers can be cited if they don’t provide adequate training to workers on how to use them correctly.
8. Scaffolding: Scaffolding violations often stem from improper construction, lack of guardrails, or failure to ensure scaffolds can support the required weight. These violations put workers at risk of falls or structural collapse.
9. Eye and Face Protection: Employers are required to provide proper personal protective equipment (PPE) for tasks involving flying particles, chemicals, or light radiation. Violations include not supplying PPE, not enforcing its use, or failing to replace damaged gear.
10. Machine Guarding: Moving machine parts can cause severe injuries, including amputations. Violations occur when employers fail to install guards, maintain equipment, or protect workers from points of operation, ingoing nip points, and rotating parts.

The industry you work in will determine which of these risks your organization faces. If you work in a high-risk industry, such as Construction or Manufacturing, it is paramount that you have defenses in place to keep people safe from common hazards. Remember: even a minor infraction can seriously impact your reputation or lead to fines.

While OSHA violations may seem daunting, they are largely preventable. Here are practical steps companies can take to stay compliant and keep workers safe:

• Regular Training: Employees should be trained not only when they are first hired but also on an ongoing basis. Training should cover OSHA standards, company-specific safety policies, and hands-on demonstrations for using equipment and PPE. Refresher training helps reinforce good habits and addresses new hazards as they emerge. Today, many organizations have begun conducting training online, utilizing Learning Management Systems (LMS), such as Capability, for safety training. For more information on online training, click here.
• Routine Inspections: Conducting frequent workplace inspections helps identify hazards before OSHA does. Supervisors should regularly check ladders, scaffolding, machinery, and PPE for wear and tear. Any deficiencies should be corrected immediately.
• Clear Documentation: OSHA requires records of training, inspections, injury reports, and equipment maintenance. Accurate documentation is also invaluable during an OSHA inspection, showing proof of compliance efforts.
• Safety Equipment: Providing proper Personal Protective Equipment (PPE) is only the first step. Employers must also ensure workers know how to use it and enforce its use. Equipment like harnesses, respirators, and eye protection should be properly maintained, fitted, and replaced as needed.
• Strong Safety Culture: Safety should be part of the company’s core values, not an afterthought. A strong safety culture encourages employees to report hazards, speak up about unsafe conditions, and participate in safety discussions without fear of retaliation.
• Compliance Programs: Companies should establish safety programs with designated safety officers or committees. These programs should include regular audits, incident investigations, and updates on OSHA standards. Subscribing to OSHA updates or partnering with safety consultants can help organizations stay current.

It is important to keep in mind that, while all violations are preventable, there is no way to eliminate incidents entirely. Just because you have everything in place to give your team the best chance to succeed, this doesn’t mean mistakes will never happen. Because human error exists, there is no way to have a 0% incident rate. The goal in these safety measures is not to completely prevent incidents, but rather to ensure people are protected and know what to do immediately following an incident.

The most common OSHA violations are not mysterious. As we’ve discussed in this article, the same issues appear year after year, which means companies have the advantage of knowing where to focus their efforts. Investing in training, inspections, documentation, and a culture of safety can help organizations not only avoid costly fines, but also protect the people who make their business possible. Compliance is not just about meeting regulations—it’s about creating a workplace where employees feel valued and safe.

Taking proactive steps today can prevent tomorrow’s accidents and ensure long-term success. Now is the time for companies to review their safety programs, close any gaps, and commit to compliance as both a responsibility and a core value.

Capability’s online safety training courses help to educate employees on workplace safety and health regulations, policies, and best practices. These courses cover a wide range of topics, all designed to fit the needs of various industries. To find the courses you need for your business today, click here.