Every year, the Occupational Safety and Health Administration (OSHA) releases data on its most frequently cited workplace safety violations. These numbers provide a revealing snapshot of the safety challenges that continue to affect American workplaces, despite decades of regulations and training programs.
The 2025 list reinforces a long-running theme: many of the most common violations are repeat offenders from prior years. Employers often struggle with issues such as fall protection, hazard communication, and machine safety problems that can have serious consequences if not addressed.
For business leaders, safety managers, and frontline supervisors, understanding OSHA’s top violations is more than a compliance exercise. It’s an opportunity to identify blind spots, strengthen safety programs, and ultimately protect workers.
Why OSHA’s Top Violations Matter for Every Business
OSHA’s annual list is not just a record of penalties; it highlights the areas where injuries and fatalities are most likely to occur. By studying the top citations, businesses can anticipate where inspectors are most likely to focus during workplace visits.
Moreover, these violations reveal common gaps in training, equipment, and supervision. Organizations that address these issues proactively can avoid fines while also reducing lost productivity, compensation claims, and employee turnover caused by unsafe conditions.
Fall Protection: The Perennial Leader in Violations
For yet another year, fall protection violations remain at the top of OSHA’s list. Employers in construction, warehousing, and manufacturing often fail to provide adequate guardrails, safety nets, or personal fall arrest systems when workers are exposed to heights of six feet or more.
The persistence of fall protection citations underscores a simple reality: falls remain one of the leading causes of workplace fatalities. Businesses must do more than provide equipment—they need to ensure workers are trained in its proper use and that supervisors consistently enforce safe practices.
Hazard Communication: Clear Information Saves Lives
Second on OSHA’s list, hazard communication violations highlight failures to properly label hazardous substances, maintain safety data sheets, or train workers in chemical handling.
In industries such as cannabis cultivation, food processing, or general manufacturing, employees often work with fertilizers, solvents, or cleaning agents that can pose risks if mishandled. Employers that lack a structured hazard communication program leave workers vulnerable to exposure and confusion during emergencies.
A strong program includes standardized labeling, accessible safety data sheets, and training that goes beyond formality to ensure real comprehension.
Respiratory Protection: Equipment Without Training is Not Enough
Respiratory protection consistently ranks high on OSHA’s list, and 2025 is no exception. Violations typically involve failing to fit-test workers, neglecting to develop written respiratory protection programs, or providing the wrong type of respirator for the hazard.
Industries with dust, smoke, or chemical vapors—such as construction, agriculture, and industrial manufacturing face particular risks. Workers may receive respirators, but without proper training, fit testing, and ongoing program evaluations, the gear is far less effective.
Ladders and Scaffolding: Everyday Tools, Everyday Hazards
Improper use of ladders and scaffolding continues to generate thousands of citations annually. These are tools so common that workers often underestimate the risks. Common violations include using ladders on unstable surfaces, exceeding weight capacities, or failing to secure scaffolds with guardrails.
Even minor oversights can lead to major injuries. Employers should train workers not only in setup and inspection but also in recognizing when equipment is unsafe to use.
Machine Guarding: Protecting Workers From Moving Parts
Machine guarding violations point to a recurring problem in manufacturing environments where employees interact with presses, saws, conveyors, or mixers. OSHA requires that dangerous moving parts be physically guarded to prevent amputations, entanglement, or crushing injuries.
In many cases, violations stem from guards being removed for convenience or machines being operated without proper barriers. Regular inspections, combined with a strong lockout/tagout program, are essential for preventing these incidents.
Lockout/Tagout: Controlling Hazardous Energy
Closely tied to machine safety, lockout/tagout (LOTO) violations are another mainstay of OSHA’s top list. These rules require employers to control hazardous energy—such as electricity, hydraulics, or compressed air—when servicing or repairing equipment.
Too often, employers lack written procedures, fail to train employees, or allow shortcuts that expose workers to sudden releases of energy. Implementing a rigorous LOTO program not only prevents serious injuries but also fosters a culture of discipline and accountability in operations.
Powered Industrial Trucks: Forklift Safety Still a Concern
Forklifts and other powered industrial trucks are indispensable in warehouses, retail distribution centers, and manufacturing plants. Yet OSHA continues to cite employers for failing to train operators, maintain equipment, or ensure safe operating conditions.
Forklift-related incidents frequently involve collisions, tip-overs, or struck-by accidents—many of which can be prevented through proper training and vehicle maintenance. Employers should integrate forklift safety into daily operations, ensuring that training is practical and ongoing.
Electrical Safety: Wiring and Equipment Issues
Improper wiring, exposed conductors, and inadequate grounding often appear in OSHA’s list of violations. These electrical hazards can lead to fires, shocks, or electrocutions if left unchecked.
In many workplaces, electrical issues stem from temporary fixes, poor maintenance, or outdated equipment. Employers must invest in qualified personnel to inspect and maintain systems regularly while enforcing safe practices around energized equipment.
Personal Protective Equipment: The Last Line of Defense
Finally, violations related to personal protective equipment (PPE) highlight gaps in providing, maintaining, or enforcing the use of safety gear. PPE may include gloves, eye protection, high-visibility clothing, or specialized equipment depending on the task.
The problem is not just availability—workers often lack training in proper usage or face workplace cultures that discourage consistent PPE compliance. Leadership must reinforce PPE use as a non-negotiable standard while ensuring comfort and accessibility for employees.
What Employers Can Do to Stay Ahead of OSHA
While OSHA’s annual list may seem repetitive, the recurring nature of these violations signals where businesses continue to fall short. Employers can take proactive steps to avoid joining these statistics:
- Conduct regular audits of fall protection, hazard communication, and machine safety.
- Simplify training so workers not only receive information but also retain and apply it.
- Invest in preventive maintenance for equipment, ladders, and electrical systems.
- Empower employees to report hazards without fear of retaliation.
- Integrate safety into business strategy, not just compliance efforts.
When businesses embed safety into daily operations, compliance becomes a natural outcome rather than a scramble before inspections.
Safety Culture as the Real Solution
The top OSHA violations of 2025 underscore familiar challenges, but they also point to opportunities. Businesses that view safety as a compliance checkbox will continue to struggle, while those that build a true safety culture will reduce risk, protect employees, and gain a competitive advantage.
In the end, OSHA’s annual list is not just about penalties—it’s a roadmap for prevention. By learning from these common mistakes, employers can protect their workforce and strengthen their organizations for the future.
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