Common OSHA Violations and How to Avoid Them

Employers are responsible for maintaining safe workplaces that comply with OSHA standards. When OSHA standards are not met, the well-being of employees can be at risk, and employers can face significant fines and legal challenges. Proactively addressing OSHA compliance not only reduces liability but also promotes a safer, more productive workplace.

If your organization is overwhelmed by OSHA regulations, inspections, and safety compliance, Conn Maciel Carey's National OSHA & Workplace Safety Practice Group provides the expertise needed to safeguard your business and workforce. Call us today at (202) 715-6244.

Common OSHA Violations and Why They Occur

Many times OSHA violations stem from things like training deficiencies, inconsistent equipment maintenance, or gaps in safety protocols. Being aware of these frequent violations can provide employers with the insights needed to close compliance gaps, which minimizes both safety and legal risks. Here are some of the most commonly cited OSHA violations and the reasons they frequently occur.

Hazard Communication (1910.1200)

What It Means: Failure to properly label hazardous chemicals, inadequate employee training on chemical hazards, and incomplete or outdated safety data sheets are common hazards under the “Hazard Communication” standard. In some cases, employers may not maintain accurate records of chemical inventories, creating gaps in hazard communication.
Why It Happens: Many employers assume that employees are aware of chemical hazards without comprehensive training. Also, maintaining updated hazard communication can feel complex and lead to lapses in labeling and documentation. Without clear, accessible information on hazardous materials, employees are at greater risk of accidental exposure, especially during routine tasks or maintenance work.

Fall Protection (1926.501)

What It Means: Unsafe practices on elevated work surfaces, such as inadequate guardrails, faulty scaffolding, and lack of personal fall arrest systems, can all constitute fall protection violations. Falls are one of the leading causes of workplace injuries and fatalities, especially in industries with frequent work at heights, such as construction. ●
Why It Happens: Employers may underestimate the hazards associated with elevated workspaces or not prioritize investments in fall prevention equipment. In some cases, time pressures or budget constraints lead to shortcuts in providing necessary safety equipment or properly installing it. Another reason could be employees not receiving adequate fall prevention training, which increases the risk of accidents

Respiratory Protection (1910.134)

What It Is: Absence of a respiratory protection program, lack of fit testing, and insufficient maintenance of respiratory equipment are recurring problems. Employers may also put employees at risk of inhaling dangerous substances by not providing appropriate respirators for specific workplace hazards.
Why It Happens: Employers sometimes overlook formal respiratory programs, assuming other safety measures are adequate to protect employees from airborne hazards. It may come from a lack of awareness about the specific risks associated with prolonged exposure to dust, fumes, or chemicals in the workplace

Lockout/Tagout (1910.147)

What It Is: Inconsistent procedures for controlling hazardous energy during maintenance, lack of proper equipment isolation, and failure to use lockout/tagout devices are common violations. When workers are unaware of proper lockout/tagout procedures, they risk exposure to machinery that can accidentally start during servicing.
Why It Happens: Many violations occur when lockout/tagout procedures are seen as secondary to productivity, particularly in time-sensitive maintenance tasks. A lack of clear policies, insufficient training, or inconsistent enforcement across shifts can lead employees to bypass lockout/tagout procedures and increase the risk of severe injuries.

Machine Guarding (1910.212)

What It Is: Lack of physical guards on machinery, failure to maintain or replace worn guarding equipment, and outdated machine safety protocols are common problems. In many cases, machine guarding is removed for repairs or adjustments and not reinstalled, leaving workers vulnerable to injury.
Why It Happens: Machine guards can sometimes interfere with maintenance and lead to their removal without replacement. Employers may lack a robust system for inspecting and updating guards, especially on older equipment. Over time, this increases the risk of worker injury from moving machine parts, especially in manufacturing and industrial environments.

Electrical Wiring Methods (1910.305)

What It Is: Use of unsafe wiring methods, failure to ground electrical systems properly, and inadequate maintenance of electrical components contribute to this frequent violation. Over time, neglected electrical wiring can degrade and create fire risks and safety hazards for employees.
Why It Happens: Routine inspections and upkeep of electrical systems may be overlooked, especially in older facilities or during periods of rapid growth. Without regular assessment by qualified personnel, hazardous wiring conditions can go unnoticed. Sometimes unqualified workers may perform temporary electrical fixes, which only increases the risk of fires or electric shock injuries.

Proactive OSHA Compliance

Taking steps to prevent OSHA violations before they happen is much less costly and disruptive than responding to citations after you receive them. Proactivity in OSHA compliance not only reduces the risk of fines and minimizes legal exposure, but it also creates a safer environment for employees, which ultimately benefits the company as a whole. Here is a breakdown of the costs and benefits associated with proactive compliance:

Cost of Non-Compliance

Fines and Penalties: OSHA citations carry significant fines, especially for repeat offenses or serious violations. Fines and penalties can escalate rapidly, especially for larger companies.
Legal and Settlement Costs: OSHA violations often lead to legal disputes and settlements, adding financial strain and potential damage to the company’s reputation.
Operational Disruptions: When OSHA violations are cited, employers may face work stoppages or required changes to their operations, affecting productivity and leading to costly delays.

Benefits of Proactive Compliance

Long-Term Cost Savings: Preventative measures, such as routine audits and employee training, reduce the likelihood of expensive citations and fines.
Improved Workplace Safety: A proactive compliance strategy creates a safer environment, decreasing accident rates, which in turn reduces downtime, worker’s compensation claims, and insurance premiums.
Enhanced Employee Morale and Retention: When employees feel safe and valued, they are more likely to stay with the company, fostering loyalty and decreasing turnover.

In addition to minimizing both operational and financial risks, a proactive approach positions your company as a safe, reliable employer. Investing in safety measures now will help you avoid disruptions and focus on long-term success.

Strategies to Prevent Common OSHA Violations

Implementing structured programs and targeted initiatives can help employers address potential hazards before they lead to serious incidents or costly citations. Here are key strategies to strengthen compliance and reduce risks:

Get to Know OSHA Standards

Stay Informed on Regulations: OSHA regulations can vary by industry and are periodically updated. Employers should regularly review standards relevant to their operations and monitor any regulatory changes.
Utilize OSHA Resources: OSHA offers guidelines, publications, and online tools to help employers understand and meet compliance requirements.
Engage Qualified Advisors: Consulting with professionals who specialize in OSHA compliance can provide valuable insights into industry-specific regulations and best practices.

Employee Training

Safety Training Programs: Establish a comprehensive training program that addresses general safety practices, as well as role-specific hazards.
Regular Refresher Courses: Provide ongoing training to make sure that employees stay aware of safety protocols and are up-to-date on the latest compliance information.
Hands-On and Practical Training: Incorporate practical training sessions where employees can practice procedures, such as proper equipment use and emergency response actions, to reinforce safe practices.

Comprehensive Safety Audits

Conduct Routine Inspections: Regular audits help identify potential hazards and provide certainty that equipment, practices, and facilities are operating well and meeting OSHA standards.
Address Issues Promptly: Quickly resolving any issues identified during audits prevents them from developing into more significant risks or workplace accidents.
Document Findings and Actions: Keep detailed records of each audit, including any corrective measures taken, as documentation can demonstrate proactive compliance efforts in the event that OSHA inspects your facility.

Violation-Specific Tips

Hazard Communication: Make certain that all hazardous materials are clearly labeled, provide employees with updated safety data sheets, and conduct routine training on chemical risks.
Fall Protection: Install guardrails or fall arrest systems on elevated work surfaces, conduct risk assessments, and offer fall protection training for employees working at heights.
Respiratory Protection: Implement a respiratory protection program that includes fit testing, regular equipment maintenance, and ongoing health evaluations for employees.
Lockout/Tagout: Establish clear lockout/tagout procedures, train employees on equipment isolation methods, and perform regular checks to verify compliance.
Machine Guarding: Install physical guards on machinery, conduct routine inspections, and reinforce safety protocols to make sure that employees remain protected from moving parts.
Electrical Safety: Schedule routine inspections of electrical systems, use certified electricians for repairs, and verify proper grounding practices to reduce the risk of electrical hazards.

Strengthening OSHA compliance goes beyond meeting minimum standards and relies on consistent action and accountability. Employers who actively address safety gaps not only reduce violations but also create a workplace where employees feel valued and protected. Ultimately those actions leads to fewer disruptions, improved productivity, and long-term operational stability..

How Conn Maciel Carey Can Assist

Conn Maciel Carey offers employers the expertise and support needed to build comprehensive and effective OSHA compliance strategies. With a team of attorneys experienced in workplace safety, we provide guidance to help employers understand OSHA regulations, address compliance issues, and create safer work environments. We are experts in:

Comprehensive Compliance Assessments: Our team conducts in-depth audits to identify potential compliance issues and recommend solutions tailored to your specific industry and operations.
OSHA Training and Education: We offer customized training programs that equip your team with the knowledge and skills needed to comply with OSHA standards. Training includes general safety protocols, hazard-specific practices, and preparation for OSHA inspections.
Support During OSHA Inspections: In the event of an OSHA inspection, we help employers thoroughly prepare, accompany them through the process, and respond to any questions or concerns raised by OSHA officials.
Guidance in Responding to Citations: If your company receives an OSHA citation, we assist in evaluating options, such as contesting the citation, negotiating penalties, or developing corrective actions to address the issue.
Ongoing Compliance Updates: OSHA regulations can change over time. We keep our clients informed about relevant regulatory updates and provide actionable insights to help them maintain ongoing compliance.

With Conn Maciel Carey’s partnership, employers can take proactive steps to enhance workplace safety, reduce compliance risks, and protect their business from the financial and operational impact of common OSHA violations. For more information or to schedule a consultation, contact Conn Maciel Carey at (202) 715-6244 or online today