These Are the 6 Most Common OSHA Violations You Should Avoid

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OSHA violations can slow down your operation, damage employee trust, and severely tarnish your company’s reputation. But thankfully, most of them are completely avoidable. By knowing where businesses commonly fall short, you can take proactive steps to stay in compliance and keep your workplace safe.

Whether you’re running a warehouse, a manufacturing plant, or a busy job site, OSHA’s most-cited violations serve as a warning list. Think of them as a roadmap that shows exactly where to focus your attention before an inspector ever sets foot on your property.

Let’s break down the six most common violations and what you can do to prevent them.

1. Fall Protection Failures

Falls remain one of the leading causes of serious injuries and fatalities in the workplace, and OSHA treats them accordingly. Most violations in this category come from missing guardrails, unsecured ladders, improper harness use, and other things of that nature.

You can avoid this pitfall by doing two things. First, ensure that fall protection systems are in place anywhere employees are working at height. Secondly, make sure those systems are actually being used correctly. This means regular equipment checks, proper anchorage points, and thorough employee training.

Even experienced workers can get complacent, so build a culture that reinforces fall safety every single day. That’s the best way to neutralize this risk and set your team up for success over the long haul.

2. Poor Hazard Communication

If your team works around chemicals, paints, solvents, or other potentially dangerous substances, you’re required to have a clear hazard communication program. This includes easy access to safety data sheets (SDS) and training that makes sure every worker understands the risks.

The mistake many companies make is assuming everyone “already knows” the hazards. But OSHA requires documented proof of training, up-to-date chemical inventories, and visible hazard signage. Keep everything organized and up-to-date so you’re not scrambling if an inspector asks for records. (Remember, good communication requires you to make sure your employees know what they’re working with and how to handle it safely.)

3. Forklift and Industrial Truck Violations

Forklifts are incredibly useful – and incredibly dangerous if operated improperly. OSHA citations in this area often come from untrained operators, a lack of daily equipment inspections, or improper load handling.

Getting your forklift operators OSHA certified is one of the easiest compliance steps you can take. In fact, online courses can get someone certified in as little as an hour. Once certified, they’ll know how to operate safely, recognize hazards, and follow load limits.

For even better results, pair certification with a daily inspection checklist to ensure brakes, steering, and safety devices are in good working order before each shift. This can prevent serious accidents.

4. Unsafe Scaffolding Practices

Scaffolding violations are a common problem in construction and industrial settings. These range from using damaged components to failing to fully plank a platform or not having proper guardrails in place.

The best prevention is a combination of strict setup protocols and regular inspections. Before anyone climbs onto a scaffold, it should be checked for stability, secure connections, and load capacity. Only trained personnel should be responsible for erecting, modifying, or dismantling scaffolding.

Always remember that shortcuts aren’t worth it. They might save you an hour today, but they can cost you weeks of downtime if they lead to an injury or violation.

5. Lack of Proper Respiratory Protection

Dust, fumes, and vapors can all cause long-term health issues if inhaled regularly. That’s why OSHA requires employers to provide appropriate respiratory protection when hazards can’t be eliminated.

Where companies go wrong is in failing to match the right respirator to the hazard or skipping annual re-training. You should have a written respiratory protection program in place, specifying when and where respirators are needed, how they’re maintained, and how employees are trained. Even if your workplace only occasionally encounters airborne hazards, that’s enough to trigger compliance requirements.

6. Electrical Wiring and Equipment Issues

Exposed wires, overloaded circuits, and missing covers are small issues that can lead to big OSHA fines and safety hazards. Many violations occur simply because equipment hasn’t been maintained or electrical work was done without following proper codes.

Prevention here is pretty straightforward. You’ll want to schedule routine inspections of all electrical systems, make repairs immediately, and only use qualified electricians for any modifications or installations. In addition, train your team to recognize and report electrical hazards before they become an emergency.

7. Putting It All Together

Avoiding these common OSHA violations is ultimately about creating a workplace where safety is built into everything you do. That means having written programs, keeping documentation current, and ensuring your team is well-trained and engaged.

It also means staying proactive. So, don’t wait for an accident or an inspector to show up before you take action. Schedule internal audits, walk the floor regularly, and encourage employees to speak up when they notice hazards.

Small, consistent actions like these can save you from massive headaches later. Compliance may seem like a burden at times, but it’s really just the framework for keeping your people safe and your operation running smoothly.