Every year, thousands of workplace accidents happen due to preventable safety violations. OSHA (Occupational Safety and Health Administration) enforces safety standards to reduce these risks, yet many businesses fail to comply.
OSHA annually lists the most frequently cited violations, highlighting the most common workplace hazards. Employers often fail to follow these rules, leading to preventable accidents, injuries, and costly violations. By being aware of these common issues, you can take proactive steps to fix safety gaps, protect workers, and avoid penalties.
Employers who do not follow these safety rules put their workers at risk and face serious financial consequences. Workplace injuries can also result in lost work time, higher insurance costs, and possible legal trouble.
In this blog, we’ll explore OSHA’s Top 10 Most Frequently Cited Standards for 2024, breaking down each standard, common violations, and practical steps to stay compliant to help you remain compliant and protect your employees.
OSHA’s Top 10 Most Cited Standards in 2024
Fall Protection General Requirements
For the 14th consecutive year, Fall Protection – General Requirements (29 CFR 1926.501) remains the most cited violation. Falls are one of the leading causes of workplace injuries and fatalities, which is why OSHA has strict requirements for fall protection. This standard specifies when fall protection is necessary, what systems should be used, how they should be installed, and how employers must oversee compliance. You need protective measures if your workers risk falling from six feet or higher in construction or four feet in general industry.
Common Violations
Some employers don’t install guardrails, safety nets, or personal fall arrest systems where needed, exposing workers to serious fall hazards. Even when fall protection systems are in place, they may not be installed correctly.
A guardrail that isn’t adequately secured or a personal fall arrest system that isn’t anchored correctly can be just as dangerous as having no protection. Supervisors sometimes fail to ensure workers use fall protection gear correctly. Employees may bypass safety measures due to time constraints, lack of awareness, or inadequate oversight.
Prevention Tips
To comply with OSHA’s fall protection requirements and keep your workers safe, you should:
| Assess Your Workplace Regularly
Install Proper Protection Train Your Employees Thoroughly Supervise and Enforce Rules |
Hazard Communication
If your workplace uses hazardous chemicals, OSHA’s Hazard Communication Standard (HCS) (29 CFR 1910.1200) ensures that employees know what they are dealing with and how to stay safe. You are required to provide information about the chemicals used, their risks, and the necessary precautions. This is done through proper labeling, Safety Data Sheets (SDS), and training programs. The goal is to prevent chemical-related injuries, illnesses, and exposure incidents.
Common Violations
OSHA requires a documented plan detailing how you communicate chemical hazards to employees. Many workplaces either lack this program or have an outdated or incomplete version. All hazardous chemicals must have clear and accurate labels. Some companies fail to include proper hazard warnings or use incorrect or missing labels, which can lead to confusion and accidents.
Every hazardous chemical must have an SDS outlining its properties, hazards, and safety precautions. If employees can’t easily access these sheets, they may not know how to handle a chemical safely. Workers must understand how to read labels, locate SDSs, and safely use chemicals. Employees who aren’t appropriately trained may mishandle hazardous materials, increasing the risk of exposure, burns, or poisoning.
Prevention Tips
To stay compliant and protect your workforce, follow these best practices:
|
Develop a Comprehensive Hazard Communication Program Ensure Proper Labeling Maintain Up-to-Date Safety Data Sheets Train Employees Regularly |
Ladders
Ladders are commonly used in many workplaces, but if they are not used properly, they can lead to serious injuries or fatalities. This OSHA standard (29 CFR 1926.1053) establishes ladder construction, maintenance, and safe use requirements to prevent falls and accidents. Whether using step ladders, extension ladders, or fixed ladders, you must ensure they are in good condition and used correctly.
Common Violations
Workers often use ladders with cracks, bent rungs, or missing safety feet. A damaged ladder can break under weight, causing falls. Standing on a ladder’s top rung or step is one of the most dangerous and common mistakes. This can cause a loss of balance and result in a fall.
A ladder can slip or tip over if it is not adequately secured. This is especially dangerous on smooth surfaces or in windy conditions. Workers sometimes use ladders as makeshift scaffolding, lean them at unsafe angles, or exceed their weight limit. These actions increase the risk of falls and structural failure.
Prevention Tips
To comply with OSHA regulations and prevent ladder-related injuries, follow these best practices:
| Inspect Ladders Before Use
Train Employees on Safe Ladders Use Secure Ladders Properly Use Ladders for Their Intended Purpose |
Respiratory Protection
OSHA’s respiratory protection standard (29 CFR 1910.134) protects workers from inhaling hazardous substances like dust, fumes, vapors, and gases. If your workplace contains respiratory hazards, you must have a written program to provide employees with the proper protective equipment and training.
Common Violations
OSHA requires a documented plan outlining how respiratory hazards will be managed. Many workplaces either lack this plan or fail to update it regularly. Employees needing respirators must undergo medical evaluations to ensure they can use them. Some employers neglect this step, putting workers at risk.
Tight-fitting respirators must be fit-tested to ensure they create an effective seal. If they don’t fit properly, they won’t provide adequate protection. Many workplaces either don’t conduct fit testing or don’t perform it correctly. Workers must understand how to use, clean, and maintain their respirators. They may wear them incorrectly or fail to replace filters when needed without proper training.
Prevention Tips
To protect your employees from respiratory hazards and ensure compliance with OSHA regulations, follow these steps:
| Develop a Comprehensive Respiratory Protection Program
Conduct Medical Evaluations Perform Fit Testing Provide Regular Training |
Control of Hazardous Energy
When machines are being repaired, serviced, or maintained, they must be completely shut down to prevent unexpected startup or release of hazardous energy. OSHA’s Lockout/Tagout (LOTO) standard (29 CFR 1910.147) is made to protect workers from injuries caused by accidental machine activation. If energy sources like electrical, hydraulic, pneumatic, or mechanical power aren’t controlled, employees risk serious injury or even death.
Common Violations
Some employers don’t have a written lockout/tagout program in place, leaving workers without clear instructions on how to prevent accidental machine startup. Employees who work with machinery must be trained on LOTO procedures, but training is often skipped or not reinforced over time. Workers may not understand when or how to apply energy control measures.
Lockout/tagout devices, such as padlocks and tags, are sometimes not applied correctly or consistently, making energy control measures ineffective. Even if a lockout/tagout program is in place, it must be reviewed and updated periodically to ensure its effectiveness. Many workplaces fail to conduct these inspections.
Prevention Tips
To stay compliant with OSHA standards and protect employees, you should:
| Develop and Document a Lockout/Tagout Program
Train All Employees on LOTO Procedures Consistently Apply Lockout/Tagout Devices Conduct Periodic Inspections |
Powered Industrial Trucks
Powered industrial trucks, including forklifts and motorized hand trucks, are used in warehouses, factories, and construction sites. While they are essential for moving materials efficiently, they also pose serious safety risks if they are not operated or maintained correctly. OSHA’s standard (29 CFR 1910.178) for powered industrial trucks sets safety requirements for design, maintenance, and operation to reduce the risk of accidents.
Common Violations
OSHA requires only trained and certified operators to use powered industrial trucks. Some workplaces allow untrained employees to operate these vehicles, increasing the risk of crashes and injuries. Daily inspections ensure that forklifts and other trucks are in safe working condition. Many employers skip these checks, leading to undetected mechanical failures.
Exceeding a forklift’s weight capacity or improperly stacking loads can cause tipping, instability, or dropped loads, putting workers at risk. Forklifts with faulty brakes, steering issues, or broken parts should never be used. However, some companies continue using defective equipment instead of removing it from service for repairs.
Prevention Tips
To ensure the safe operation of powered industrial trucks and prevent OSHA violations, follow these best practices:
| Implement a Training and Certification Program.
Conduct Daily Inspections and Routine Maintenance. Follow Manufacturer Guidelines for Loading. Immediately Remove Defective Equipment from Service. |
Fall Protection Training Requirements
Working at heights requires proper training to recognize fall hazards and protect themselves. OSHA’s fall protection training requirements(29 CFR 1926.503) ensure workers understand the risks, how to use fall protection systems, and what emergency procedures to follow. Without this training, employees may not use safety equipment correctly, increasing the risk of serious injuries or fatalities.
Common Violations
Some workplaces don’t have a structured fall protection training program. Without standardized training, workers may not know how to use safety gear or recognize fall risks. Workers must be retrained when new fall protection systems or equipment are introduced. Some employers neglect this step, leading to improper use of updated equipment.
OSHA requires records of all training sessions, including dates, topics covered, and employee participation. Many employers fail to maintain these records, making it difficult to prove compliance.
Prevention Tips
To comply with OSHA standards and ensure worker safety, follow these steps:
| Develop a Comprehensive Training Program.
Ensure Training is Thorough and Up to Date. Keep Detailed Training Records. Regularly Review and Improve Training Materials. |
Scaffolding
Scaffolds provide workers with elevated platforms to perform tasks safely, but if not built or used correctly, they can lead to serious falls and injuries. OSHA’s scaffolding standard (29 CFR 1926.451) sets design, construction, and use requirements to ensure worker safety. Proper scaffolding prevents accidents caused by collapse, instability, or falls from height.
Common Violations
To prevent falls, scaffolds must have guardrails, midrails, and toeboards. Employers who fail to install these protections put workers at serious risk. Every scaffold has a weight limit. Exceeding this limit can cause structural failure, leading to collapse. Many workers overload scaffolds with equipment or materials without checking capacity guidelines.
OSHA requires a competent person to inspect scaffolds before each shift to check for defects or hazards. Skipping this inspection increases the chance of using unsafe scaffolding. Some workers stack ladders, boxes, or other objects on scaffolds to reach higher areas. This practice is hazardous and can lead to instability and falls.
Prevention Tips
To ensure scaffolding is used safely and remains OSHA-compliant, follow these best practices:
| Design and Construct Scaffolds according to OSHA Standards.
Install Proper Guardrails and Fall Protection. Conduct Inspections Before Every Shift. Prohibit Unsafe Extensions |
Eye and Face Protection
Employees who work in environments exposed to flying particles, molten metal, chemicals, or caustic liquids must wear proper eye and face protection. OSHA’s standard (29 CFR 1926.102) ensures workers have the right protective gear to prevent burns, blindness, or long-term eye damage. Safety glasses, goggles, and face shields play a critical role in protecting against these hazards, but they must meet industry standards and be properly maintained.
Common Violations
Some workers are exposed to hazards without being given proper protective equipment. In many cases, they rely on inadequate eyewear or nothing at all. Protective eyewear must meet ANSI Z87.1 standards to ensure durability and impact resistance. Many employers either overlook this requirement or use substandard equipment. Over time, protective eyewear can become scratched, cracked, or worn out, reducing visibility and effectiveness. Workers may continue using these damaged items because replacements aren’t readily available.
Prevention Tips
To ensure compliance and protect employees from eye and face injuries, follow these steps:
| Conduct a Hazard Assessment.
Provide OSHA-Compliant Eye and Face Protection. Train Employees on Proper Use and Maintenance. Inspect and Replace Damaged Equipment Regularly. |
Machine Guarding
Machines with moving parts, sharp edges, or rotating components can pose serious worker risks. OSHA’s machine guarding standard (29 CFR 1910.212) requires that employers install protective barriers to prevent injuries such as cuts, amputations, and crushing incidents. Machine guards are essential safety features that shield workers from direct contact with dangerous parts while allowing the machines to function correctly.
Common Violations
Some workers remove or bypass machine guards to speed up tasks, increasing the risk of serious injuries. Employees may forget to reinstall or adequately secure the guards after servicing a machine, exposing others to hazards.
Workers sometimes disable interlocks or override safety mechanisms to increase efficiency. This creates a hazardous work environment. Employees may not understand the importance of machine guards or how they work, leading to improper use or removal.
Prevention Tips
To prevent machine-related injuries and maintain OSHA compliance, follow these best practices:
| Install Proper Machine Guards
Develop and Enforce a Lockout/Tagout (LOTO) Program Regularly Inspect Machinery Train Employees on the Importance of Machine GuardingTrain Employees on the Importance of Machine Guarding |
Enforcing these safety measures can reduce the risk of severe machine-related injuries and create a safer workplace for your employees.
The Importance of Workplace Safety Training
Workplace safety training is essential for preventing accidents, reducing injuries, and ensuring compliance with industry regulations. A well-trained workforce is the key to minimizing risks and responding effectively when incidents occur.
Safe T Professionals is committed to strengthening workplace safety through expert training and staffing solutions. Through a strategic partnership, Gallagher Bassett enhances this mission by offering onsite, in-person, and hybrid training courses led by certified trainers. Their expanded national reach provides businesses with comprehensive safety training and post-incident support, ensuring workers are prepared for prevention and recovery. These programs provide employees with hands-on knowledge and real-world safety applications, ensuring they are ready for potential workplace hazards.
This collaboration enhances the availability of expert safety training and staffing solutions, equipping your organizations with the tools you need to prevent accidents and improve overall workplace safety.
Mitigate Workplace Hazards with Safe T Professionals’ Safety Solutions
At Safe T Professionals, we are dedicated to elevating safety standards through our expert consulting and staffing services. By proactively addressing and preventing safety issues and equipping your workforce with the necessary knowledge and tools, we help create a safer work environment.
Partner with Safe T Professionals to enhance your company’s safety protocols and ensure compliance with industry standards. Whether you are looking to fill safety-specific roles or need expert consultation to mitigate workplace hazards, we are here to help.
Connect with us today!
