10 Most Common OSHA Penalties and Tips to Avoid Them

Businesses can avoid costly OSHA penalties by understanding common violations and implementing proactive safety measures to protect workers.

• By Elis Enano
• Sep 12, 2024

Think of OSHA as the protector of workers' safety at work. But sometimes, businesses don't follow the safety rules, leading to OSHA violations. These violations can be serious and result in hefty fines or even legal trouble. Businesses face the challenge of keeping their workplaces safe while following all the rules. Knowing about OSHA violations helps us to understand the importance of workplace safety and how to make workplaces safer for everyone.

Let’s learn more about OSHA violations as well as the precautionary measures to avoid them.

Top Cited OSHA Violation 2023:

Fall Protection – General Requirements (1926.501): 7,271 violations

Hazard Communication (1910.1200): 3,213 violations

Ladders (1926.1053): 2,978 violations

Scaffolding (1926.451): 2,859 violations

Powered Industrial Trucks (1910.178): 2,561 violations

Lockout/tagout (1910.147): 2,554 violations

Respiratory requirements (1910.134): 2,481 violations

Fall protection – training requirement (1926.503): 2,112 violations

Eye and face protection (1926.102): 2,074 violations

Machine Guarding (1910.212): 1,644 violations

• Fall Protection – General Requirements (1926.501)

Falls are a leading cause of fatalities in the construction industry, and in 2023, violations related to fall protection continued to top OSHA's list. Employers frequently failed to provide proper fall protection systems such as guardrails, safety nets or personal fall arrest systems. According to BLS, 5190 workplace injuries that led to workers' deaths were associated with elevations and falls. Common infractions included inadequate protection on elevated work surfaces, unprotected sides and edges, and improper use of fall protection equipment. Ensuring workers are equipped and trained to use these systems correctly is critical to preventing fall-related injuries and deaths.

• Hazard Communication (1910.1200)

Effective communication about hazardous chemicals in the workplace remains a critical safety requirement. Violations in 2023 often stemmed from the absence of proper labeling, lack of Safety Data Sheets (SDS) and insufficient employee training on handling hazardous substances. As per research, a total of 3,213 workplaces were cited in 2023 for failing to comply with the requirement for Hazard Communication. These lapses can lead to serious health risks for workers exposed to chemicals without adequate information or protection. Employers must maintain updated hazard communication programs to mitigate these risks and ensure compliance with OSHA standards.

• Ladders (1926.1053)

Ladder-related violations frequently occur in both construction and general industry settings. Common issues included using ladders that were damaged or not designed for the specific task, improper ladder use and failure to secure ladders properly. In 2023, such violations often resulted in falls and injuries, highlighting the need for proper ladder inspection, maintenance and training on safe ladder practices to avoid accidents.

• Scaffolding (1926.451)

Scaffolding violations remained a prevalent issue in construction. Problems included inadequate fall protection, improper scaffold construction and lack of proper access. These violations pose significant risks, as improper scaffolding can lead to collapses and severe worker injuries. Employers must ensure scaffolding is correctly assembled, regularly inspected and equipped with the necessary fall protection measures to maintain worker safety.

• Powered Industrial Trucks (1910.178)

Violations involving powered industrial trucks, such as forklifts, were often related to improper operation, lack of operator training and inadequate maintenance. These infractions frequently led to accidents involving collisions, tip-overs and pedestrian injuries. Employers must ensure that operators are thoroughly trained and certified and that equipment is regularly inspected and maintained to prevent workplace accidents.

• Lockout/Tagout (1910.147)

Lockout/tagout (LOTO) procedures are crucial for protecting workers from the unexpected energization of machines during maintenance. In 2023, frequent violations included the absence of proper LOTO procedures, inadequate employee training and failure to utilize energy control devices correctly. These lapses can result in serious injuries or fatalities, emphasizing the importance of comprehensive LOTO programs and adherence to proper procedures to safeguard workers.

• Respiratory Requirements (1910.134)

Violation of respiratory protection standards frequently occurs when employers fail to implement written respiratory protection programs, conduct proper fit testing for respirators or provide medical evaluations for employees required to use respirators. Inadequate respiratory protection exposes workers to respiratory hazards such as harmful dust, fumes or chemicals, increasing the risk of respiratory illnesses or injuries. Employers must prioritize respiratory safety measures to protect workers and comply with OSHA regulations.

• Fall Protection – Training Requirement (1926.503)

More than 800 workers lost their lives in 2018 due to slip, trip and fall accidents. Inadequate training on fall hazards and proper use of fall protection equipment is a common violation in industries where workers are exposed to elevated surfaces. Employers often fail to provide comprehensive training programs or ensure that workers understand the importance of using fall protection equipment correctly. Effective training is crucial for empowering workers to recognize fall hazards, use protective equipment and prevent accidents, thereby ensuring compliance with OSHA regulations and promoting a safe work environment.

• Eye and Face Protection (1926.102)

Eye and face protection violations commonly occur in industries where workers are exposed to flying debris, chemicals or other hazardous substances. In 2023, issues included the absence of proper protective gear, non-compliance with safety standards and insufficient training on equipment use. Protecting workers' eyes and faces from injuries requires consistent use of appropriate PPE and adherence to safety protocols.

• Machine Guarding (1910.212)

Machine guarding violations involve inadequacies in safeguarding workers from moving parts, flying debris or other hazards associated with machinery. Failure to install proper machine guards can lead to serious injuries, including amputations and crush incidents. Employers must prioritize machine safety by implementing effective guarding measures, conducting regular inspections, and providing appropriate training to workers operating or working near machinery.

Best Tips to Avoid OSHA Penalties 

• Stay informed about OSHA regulations. Regularly review and stay updated on OSHA regulations relevant to your industry. Subscribe to newsletters, attend seminars, or utilize online resources to stay informed about changes or updates in standards. Understanding regulatory requirements is crucial for maintaining compliance and avoiding penalties.

• Conduct regular safety inspections. Implement a robust safety inspection program to identify and address potential hazards in the workplace. Conduct regular inspections of equipment, machinery and work areas to ensure compliance with safety standards. Promptly address any issues or deficiencies to mitigate risks and demonstrate a commitment to workplace safety.

• Provide comprehensive employee training. Invest in comprehensive training programs to educate employees about workplace hazards, safety protocols and OSHA regulations. Ensure that all workers receive proper training on equipment operation, hazard recognition, emergency procedures and the use of personal protective equipment (PPE). Well-trained employees are more likely to adhere to safety protocols, reducing the risk of accidents and OSHA violations.

• Establish a safety committee. Form a safety committee comprising management and employee representatives to oversee safety initiatives and promote a culture of safety in the workplace. Encourage open communication and collaboration among committee members to identify safety concerns, develop solutions, and implement proactive measures to prevent accidents and OSHA violations.

• Address seasonal hazards like heat stress. Take a proactive approach to seasonal hazards such as heat stress. Implement strategies like providing adequate hydration, scheduling frequent breaks in cool areas, and educating workers about the signs and symptoms of heat-related illnesses. You must have an updated heat stress program to deal with the evolving challenges related to this hazard. Similarly, protect employees from cold stress by making sure they have appropriate clothing, access to warm shelters and frequent breaks to warm up. 

• Maintain accurate records. Maintain thorough and accurate records of safety training, inspections, incidents and corrective actions taken to address hazards. Organize documentation in a readily accessible format to demonstrate compliance with OSHA regulations during inspections or audits. Well-maintained records not only facilitate compliance but also serve as evidence of proactive safety measures.

• Prioritize hazard communication. Implement a robust hazard communication program to ensure that employees are aware of potential workplace hazards and understand how to protect themselves. Provide clear labeling of hazardous chemicals, maintain Safety Data Sheets (SDS), and conduct regular training on chemical handling and exposure prevention. Effective hazard communication fosters awareness and compliance with OSHA standards.

• Encourage employee engagement. Foster a culture of safety by encouraging active participation and engagement from employees at all levels. Encourage workers to report safety concerns, suggest improvements, and participate in safety committees or training sessions. Empowering employees to take ownership of safety promotes vigilance and accountability, reducing the likelihood of OSHA violations.

• Implement corrective actions promptly. Address any identified hazards or deficiencies promptly by implementing corrective actions. Develop and follow through with corrective action plans to rectify safety issues identified during inspections or incident investigations. Prompt and effective corrective actions demonstrate a commitment to continuous improvement and mitigate the risk of recurring violations or accidents.

• Engage in regular safety meetings. Conduct regular safety meetings or toolbox talks to reinforce safety procedures, discuss relevant OSHA standards and address emerging safety concerns. Use these opportunities to communicate updates, share best practices and solicit feedback from employees regarding safety initiatives. Regular safety meetings promote awareness, engagement and a collective commitment to maintaining a safe work environment.

• Seek professional guidance. When in doubt, seek professional guidance from safety consultants, industry associations or legal experts specializing in OSHA compliance. Consulting with knowledgeable professionals can help clarify regulatory requirements, identify areas for improvement, and develop tailored strategies to ensure compliance and minimize the risk of OSHA penalties.

Conclusion

The fact is OSHA penalties can have a significant financial and reputational impact on businesses. But, once companies understand the common violations and tips to avoid them, they can surely create a safer work environment. Eventually, they can also avoid the costly OSHA penalties. To keep up with workplace safety, follow these tips, conduct regular inspections, enroll employees in OSHA training sessions and try to maintain accurate records.

By following these strategies, businesses can navigate OSHA regulations effectively and foster a safer, more compliant workplace.