Top 10 Most Common OSHA Violations

From Oct. 1, 2022 through Sept. 30, 2023, the most commonly-issued OSHA citations were in violation of the 10 categories below. These standards are a mix of construction and general industry requirements.

The following are the most commonly issued OSHA violations, in order:

1. Fall protection - general requirements (OSHA standard 1926.501)
2. Hazard communication (1910.1200)
3. Ladders (1926.1053)
4. Scaffolds - general requirements (1926.451)
5. Powered industrial trucks (1910.178)
6. Control of hazardous energy (Lockout/tagout) (1910.147)
7. Respiratory protection (1910.134)
8. Fall protection - training requirements (1926.503)
9. Personal protective and lifesaving equipment - eye and face protection (1926.102)
10. Machine guarding (1910.212)

Falls are one of the leading causes of injuries in the workplace, and lack of fall protection is almost always the top cited OSHA violation each year. Safeguard your workers with strategic planning, effective training and proper fall protection equipment.

OSHA requires that fall protection be provided at:

• 4 feet or more in general industry work
• 5 feet or more in shipyards
• 6 feet or more in construction industry work
• 8 feet or more in longshoring operations
• Any job site that includes work over dangerous machinery, regardless of elevation

Fall protection includes everything from safety harnesses to guardrails. Toe-boards, railings and floor covers should be used to protect workers from any hole or fall danger. Elevated platforms, for example, require railings and toe boards. Other means of fall protection include safety nets, handrails and stair rails.

Violations involving chemical safety often claim second position on OSHA’s Top 10 list. Make sure your workplace provides chemical labels and correct safety data sheets for effective hazard communications.

Hazard communication is necessary for chemical safety and includes:

• Hazard classification - the specific criteria of health hazards posed by the chemical, and the identity of the chemical itself
• Labels - the manufacturer-provided label that should include pictograms, hazard classifications, signal words and precautionary information
• Safety data sheets - the detailed information documents often prepared by the manufacturer that list storage information, chemical ingredients, first aid practices and other essential safety data
• Training - the workplace hazard training that must be provided by the employer for reading labels, safety data sheets and safe chemical handling

The third most cited OSHA violation in 2023 is the construction industry ladder standard. Ladder requirements are extensions of fall safety and require the ladder be completely level and have slip resistant feet. Ladder railings should extend at least 3 feet past the landing surface. When such extension is not possible, grab rails or stabilizers must be provided.

Make certain your workers know how to operate step, platform, multi-position and extension ladders properly. Also, double-check that your business provides the right ladder for the job. Your industry and the specific job determine the commercial ladder standards that apply to your business.

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Improper use of scaffolds poses a significant safety threat in the workplace. This includes all elevated, temporary work platforms.

Violations of OSHA’s scaffold standards were the fourth most cited from 2019-2020, fifth from 2021-2022 and are fourth again from 2022-2023. Follow safety standards, and choose professional
scaffolding
solutions to guard against collapses, falling objects, electrocution and other job-site dangers.

Fall protection is required when workers are on a scaffold 10 feet or more above the lower level. Scaffold requirements also include:

• Safety training for all workers who will assemble, use or dismantle a scaffold
• Standard guardrail, midrail and cross bracing height
• Level, load-bearing footings and mud sills for legs, frames, poles, braces and other support
• The necessity of a plank or deck platform on the scaffold
• Tying and bracing standards to keep the scaffold restrained and prevent tipping
• Definitions of a competent person, such as a supervisor or a certified employee, and when they must be involved

Powered work truck, or industrial truck violations are fifth place on OSHA’S Top 10 violations list for 2023, which has seen an increase from seventh place in 2018.

Forklifts are the most common type of powered industrial truck used on job sites, and they are especially common in retail. These machines pose physical risks to the operators and other personnel when safety standards are not followed.

The best ways to protect employees from machine hazards are to train all employees by best practices and choose the right equipment for the job site.
Staff must be at least 18 years old to operate a powered industrial truck on the job, and they must have completed training. General industry training and evaluation standards are set in 29 CFR 1910.178(l)(1).

Like other job site hazards, it is the employer’s responsibility to provide training and keep all equipment up to standard.
Forklifts
and lift trucks should be inspected prior to use.

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Violations of lockout/tagout, or LOTO standards are frequently listed in OSHA’s Top 10, and in 2023 they made sixth place. These safety measures protect against exposure to dangerous machines, steam and electricity. Stock and maintain lockout kits to protect your workers.

All electrical equipment scheduled for maintenance must be inoperable and completely deenergized prior to maintenance or repair work. Tag the controls on the equipment or circuits that are under repair, and lock those same controls for the safety of the worker. Create lockout and tagout procedures and guidelines to make sure that the equipment is used properly.

Lack of and improper use of respiratory equipment was OSHA’s third most common violation in fiscal year 2020, fourth from 2021-2022 and is now in seventh place for 2023. Since 2020, communities have become more conscious of respiratory safety and the proper protection against particulates and bacteria. Be familiar with the safety regulations that govern your industry, provide appropriate respiratory masks and develop a respiratory protection program to help keep your workers safe.

Respirators protect workers from vapors, fog, dust, toxic smoke and other environmental hazards. OSHA has respiratory protection standards for general industry, construction and maritime work. Airlines, hospitals, construction sites, confined spaces and many other kinds of job sites require respiratory protection for workers.

The type of respirator provided to workers should correspond to the hazards of their workplace. Respiratory protection keeps workers safe in one of two ways—by filtering contaminants or by supplying clean air. Employers are responsible for knowing the hazards in their workplace and supplying all personnel with the right type of personal protective equipment (PPE). Make sure all respirator masks fit your staff by administering fit tests.

In addition to providing fall protection at the job site, employers are responsible for fall protection training. This more specific type of fall protection violation made eighth place in 2023. While OSHA provides videos and other training resources, employers must communicate all job hazards to their personnel in plain language. For the purposes of both safety and compliance, employers should also make sure that their staff understand the training and follow best practices at work.

Fall protection training can include:

• How to inspect a ladder before use
• Using a ladder safely
• Scaffold design and security
• How to install ties, guides and braces for a scaffold
• Safe ways to get on and off of a scaffold
• Fall hazards in roofing work
• How to use PPE

Your fall protection training should be customized to your specific job site. Whether you do the training or assign it to a supervisor, do your best to engage the workers. Ask them questions, relate safety training to personal experiences and try to involve everyone in the conversation.

Eye and face protection violations have remained in ninth place since 2021-2022. This equipment should shield workers from flying objects, heat, splashes, vapors, dust and intense light with appropriate face protection and eyewear. Providing the correct PPE for your job site not only complies with industry standards, it protects your team from injuries.

Eye and face protection
are commonly required at construction sites, but must be used anywhere there is a risk of injury from:

• Flying particles
• Molten metals
• Liquid chemicals
• Acids or caustic liquids
• Chemical gases or vapors
• Potentially injurious light radiation

Employees who need
eyewear
for the workplace should also receive training on safety practices and how to avoid hazards. Any employees who require prescription glasses must be provided PPE that they can wear over them. The manufacturer should be marked on all PPE.

Moving machine parts can crush hands or even cause blindness. Failure to guard machines and protect workers is the tenth most commonly cited OSHA violation this year. Barriers, light curtains and two-hand trips are all forms of machine guards that can protect workers from industrial equipment.

For the safety of staff, machine guarding is most often required at the point of operator or where personnel will be working. However, additional points of protection may be required depending on the type of machine, type of work and job environment.

It is the employer’s responsibility to know the hazards and make sure all workers are trained accordingly. Many industrial machines include built-in safeguards from the manufacturer, but employers must still provide safeguards if they are not built into the machine. Alarms and fences are secondary forms of machine guards that can help keep workers safe. Inspect machines frequently and retrain staff as needed.

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