OSHA's Top 10 Most Cited Violations in 2025 (And How to Avoid Them)

OSHA's Top 10 Most Cited Violations in 2025 (And How to Avoid Them)

Quick Answer: Fall protection remains OSHA's #1 most cited violation in 2025 with 5,914 citations, followed by hazard communication (2,546) and ladder safety (2,405). To avoid these violations, employers must implement comprehensive safety programs, provide proper training, conduct regular inspections, and maintain detailed documentation. This guide breaks down each violation with actionable compliance checklists.

Why OSHA's Top 10 List Matters for Your Business

OSHA's Top 10 list isn't just a recap of violations—it's a roadmap for businesses to prioritize compliance efforts. These standards highlight where risks (and citations) are most common, making them a practical starting point for safety programs. In fiscal year 2025, OSHA issued 23,537 citations across the top 10 violations, representing a 17% decrease from FY 2024. However, with penalties increasing to $16,550 per serious violation in 2025, avoiding these citations is more critical than ever.

OSHA's Top 10 Most Cited Violations for FY 2025

Rank	Violation	OSHA Standard	Total Citations
1	Fall Protection – General Requirements	1926.501	5,914
2	Hazard Communication	1910.1200	2,546
3	Ladders	1926.1053	2,405
4	Lockout/Tagout	1910.147	2,177
5	Respiratory Protection	1910.134	1,953
6	Fall Protection – Training Requirements	1926.503	1,907
7	Scaffolding	1926.451	1,905
8	Powered Industrial Trucks	1910.178	1,826
9	Eye and Face Protection	1926.102	1,665
10	Machine Guarding	1910.212	1,239

Source: OSHA FY 2025 Data

1. Fall Protection – General Requirements (5,914 Violations)

The Problem: Fall protection has topped OSHA's violation list for 15 consecutive years. The majority of citations occur in construction, where unprotected edges, improper use of guardrails, and unsafe scaffolding practices put workers at serious risk.

Common Violations Include:

• Failure to provide fall protection at required heights (6 feet for construction, 4 feet for general industry)
• Missing guardrail systems on elevated platforms
• Unprotected leading edges
• Inadequate or missing personal fall arrest systems
• Lack of hole covers and floor opening protections

✅ Fall Protection Compliance Checklist

Hazard Assessment:

• ☐ Conduct thorough hazard assessment of all elevated work areas
• ☐ Identify all fall hazards 4+ feet (general industry) or 6+ feet (construction)
• ☐ Document findings in written fall protection plan Physical Controls:
• ☐ Install guardrail systems on all open-sided platforms and floors
• ☐ Provide personal fall arrest systems (PFAS) where guardrails aren't feasible
• ☐ Ensure proper anchor points capable of supporting 5,000 lbs per worker
• ☐ Install safety nets where required
• ☐ Cover or guard all floor holes and openings Equipment Inspection:
• ☐ Inspect harnesses, lanyards, and lifelines before each use
• ☐ Remove defective equipment from service immediately
• ☐ Conduct annual certified inspections of all fall protection equipment
• ☐ Maintain inspection records for minimum 3 years Training:
• ☐ Train all workers exposed to fall hazards
• ☐ Document training completion with signatures
• ☐ Provide refresher training when workplace changes or equipment updates occur

2. Hazard Communication (2,546 Violations)

The Problem: Employers were cited for lacking written hazard communication programs, failing to train employees, or not properly labeling containers of hazardous chemicals. This gap directly impacts worker awareness and safety in manufacturing, healthcare, and chemical industries.

Key 2025 Updates:

OSHA's Hazard Communication Standard now aligns with GHS Revision 7, featuring new hazard categories, improved labeling, and SDS requirements. Employers must update labeling, hazard communication programs, and employee training by July 19, 2026.

✅ Hazard Communication Compliance Checklist

Written Program:

• ☐ Develop and maintain a written HazCom program
• ☐ Update program to reflect GHS Revision 7 requirements
• ☐ Make program accessible to all employees and OSHA inspectors Safety Data Sheets (SDS):
• ☐ Maintain current SDS for every chemical used, stored, or transported
• ☐ Ensure SDS are readily accessible during each work shift
• ☐ Update SDS within 3 months of receiving revised versions
• ☐ Train employees on how to read and interpret SDS Labeling:
• ☐ Label all chemical containers with product identifier, signal word, hazard statements, and pictograms
• ☐ Update existing labels to meet GHS Revision 7 standards
• ☐ Ensure workplace labels on secondary containers
• ☐ Don't remove or deface existing labels Training:
• ☐ Train employees on chemical hazards before initial assignment
• ☐ Provide training whenever new hazards are introduced
• ☐ Cover detection methods, protective measures, and HazCom program elements
• ☐ Document all training with employee signatures

3. Ladders (2,405 Violations)

The Problem: Misuse of ladders and failure to meet ladder safety standards continue to drive incidents, especially in construction and maintenance.

Critical Requirements:

• Fixed ladders 24 feet or more require a ladder safety system or personal fall arrest system
• Portable ladders must extend 3 feet above the upper landing surface
• Maintain 4:1 ratio for non-self-supporting ladders

✅ Ladder Safety Compliance Checklist

Selection & Setup:

• ☐ Choose correct ladder type for the job (duty rating, length, material)
• ☐ Inspect ladder before first use each work shift
• ☐ Place ladder on stable, level surface
• ☐ Secure top and bottom of ladder to prevent slipping
• ☐ Maintain 3-point contact when climbing Pre-Use Inspection:
• ☐ Check for cracks, splits, or breaks in rails and rungs
• ☐ Verify all rungs are intact and evenly spaced
• ☐ Ensure feet have non-slip material
• ☐ Test locks and spreaders function properly
• ☐ Remove defective ladders from service immediately Safe Use:
• ☐ Never exceed maximum load capacity
• ☐ Don't use top 3 rungs of stepladder
• ☐ Face ladder when ascending/descending
• ☐ Don't carry tools in hands—use tool belt or hoist
• ☐ Barricade area around ladder base if in doorway or passageway

4. Lockout/Tagout (2,177 Violations)

The Problem: OSHA repeatedly finds employers not following proper lockout/tagout procedures, exposing workers to dangerous releases of energy during equipment servicing.

✅ Lockout/Tagout Compliance Checklist

Written Program:

• ☐ Develop machine-specific LOTO procedures for all equipment
• ☐ Include step-by-step shutdown, isolation, and verification procedures
• ☐ Update procedures when equipment changes Equipment:
• ☐ Provide lockout devices (locks, tags, hasps, valve covers)
• ☐ Ensure devices are durable, standardized, and identifiable
• ☐ Provide one key/combination per lock Training:
• ☐ Train authorized employees (those who perform LOTO)
• ☐ Train affected employees (those who work near equipment)
• ☐ Provide annual refresher training
• ☐ Document all training Implementation:
• ☐ Follow 6-step LOTO procedure: Prepare, Shutdown, Isolate, Apply LOTO, Release Stored Energy, Verify Isolation
• ☐ Never remove another employee's lock without proper authorization
• ☐ Conduct annual inspections of LOTO procedures

5. Respiratory Protection (1,953 Violations)

The Problem: Employers were cited for not implementing respiratory protection programs or failing to ensure fit testing and training, particularly in sectors with dust, fumes, or airborne hazards.

✅ Respiratory Protection Compliance Checklist

Program Requirements:

• ☐ Develop written respiratory protection program
• ☐ Conduct hazard assessment to determine respiratory hazards
• ☐ Select appropriate respirators based on hazards
• ☐ Provide medical evaluations for all users Fit Testing:
• ☐ Conduct fit testing before initial use
• ☐ Perform annual fit testing
• ☐ Retest when respirator model/size changes or physical condition changes
• ☐ Document all fit test results Training:
• ☐ Train employees annually on respirator use and limitations
• ☐ Demonstrate proper donning, doffing, and seal checks
• ☐ Cover maintenance, storage, and emergency procedures Program Maintenance:
• ☐ Establish cleaning and disinfection procedures
• ☐ Provide proper storage facilities
• ☐ Conduct regular program evaluations
• ☐ Maintain records for duration of employment

6. Fall Protection Training (1,907 Violations)

The Problem: Beyond physical safeguards, employers are failing to provide adequate fall protection training to workers—a critical part of compliance and prevention.

Training Must Cover:

• Nature of fall hazards in work area
• Correct procedures for erecting, inspecting, and maintaining fall protection systems
• Use and operation of guardrail, PFAS, safety net, and warning line systems
• Limitations on mechanical equipment use
• Role of safety monitor

7. Scaffolding (1,905 Violations)

The Problem: Unsafe scaffold construction, lack of guardrails, and improper access methods continue to put workers at risk of falls and serious injury.

✅ Scaffolding Safety Checklist

• ☐ Ensure scaffolds support at least 4x intended load
• ☐ Install guardrails on all open sides (top rail 38-45 inches)
• ☐ Provide proper access (ladder, stair tower, ramp)
• ☐ Inspect scaffolds before each shift by competent person
• ☐ Train workers on scaffold hazards and procedures
• ☐ Don't use unstable objects (barrels, boxes) to support scaffolds

8. Powered Industrial Trucks (1,826 Violations)

The Problem: Forklift and powered truck violations typically stem from insufficient operator training and failure to maintain equipment.

✅ Forklift Safety Checklist

Operator Training:

• ☐ Provide formal instruction (lecture, video, written material)
• ☐ Conduct practical hands-on training
• ☐ Evaluate operator performance
• ☐ Certify operators and maintain records
• ☐ Refresher training every 3 years or after incident Equipment & Operations:
• ☐ Inspect forklifts daily before use
• ☐ Remove defective trucks from service
• ☐ Ensure operators wear seat belts
• ☐ Maintain clear visibility and use spotters when needed
• ☐ Follow load capacity limits

9. Eye and Face Protection (1,665 Violations)

The Problem: Many citations involved employees not being provided with—or not using—required PPE for tasks that carry exposure risks.

✅ Eye & Face Protection Checklist

• ☐ Conduct hazard assessment to identify eye/face hazards
• ☐ Provide appropriate PPE (safety glasses, goggles, face shields)
• ☐ Ensure PPE meets ANSI Z87.1 standards
• ☐ Train employees on proper use and care
• ☐ Enforce PPE use through supervision and discipline
• ☐ Replace damaged or defective equipment immediately

10. Machine Guarding (1,239 Violations)

The Problem: Missing or inadequate machine guards expose workers to preventable contact with moving parts—one of the most serious industrial hazards.

✅ Machine Guarding Checklist

• ☐ Guard all points of operation, ingoing nip points, rotating parts, and flying chips
• ☐ Use fixed guards where possible; interlocked guards when access needed
• ☐ Ensure guards don't create new hazards
• ☐ Secure guards firmly to machine
• ☐ Never remove or bypass machine guards
• ☐ Train operators on guard requirements and hazards

Step-by-Step: Building Your OSHA Compliance Program

Phase 1: Assessment (Weeks 1-2)

1. Conduct comprehensive safety audit using OSHA's Top 10 checklist 2. Review incident reports from past 3 years to identify patterns 3. Interview workers about safety concerns and near-misses 4. Document all findings with photos and written reports

Phase 2: Planning (Weeks 3-4)

5. Prioritize hazards by severity and likelihood 6. Develop written safety programs for each applicable standard 7. Assign responsibilities to specific team members 8. Set implementation timeline with milestones

Phase 3: Implementation (Weeks 5-12)

9. Purchase necessary equipment (PPE, guards, fall protection) 10. Install engineering controls (guardrails, machine guards) 11. Conduct employee training on all new procedures 12. Post required signage and safety communications

Phase 4: Monitoring & Maintenance (Ongoing)

13. Conduct weekly safety inspections 14. Hold monthly safety committee meetings 15. Review and update programs quarterly 16. Track leading and lagging indicators 17. Investigate all incidents and near-misses

💰 The Real Cost of OSHA Violations

Violation Type	2025 Penalty	Typical Abatement Cost	Potential Workers' Comp Claims
Serious	$16,550	$5,000-$50,000	$40,000 average
Willful/Repeat	$165,500	$50,000-$500,000	$100,000+
Failure to Abate	$16,550/day	Ongoing costs	Escalating claims

Key Takeaway: Prevention costs a fraction of violation penalties plus you avoid human suffering and productivity losses.

📋 Your 30-Day Action Plan

Week 1:

• Download OSHA's Top 10 checklist
• Assign safety coordinator
• Schedule safety audit Week 2:
• Conduct fall protection assessment
• Review hazard communication program
• Inspect all ladders and scaffolding Week 3:
• Verify LOTO procedures are documented
• Check respiratory protection program
• Audit PPE availability and use Week 4:
• Review training records for all Top 10 areas
• Identify gaps and create corrective action plan
• Schedule employee training sessions

Key Takeaways

✓ Fall protection remains #1—prioritize hazard assessments and guardrail systems ✓ Documentation is critical—maintain written programs, training records, and inspection logs ✓ Training can't be overlooked—both fall protection training (#6) and general safety training prevent violations ✓ Regular inspections catch problems early—implement pre-shift and weekly safety checks ✓ 2025 penalties are steep—up to $165,500 for willful violations makes prevention essential ✓ Stay updated on standards—GHS Revision 7 and other changes require program updates

Final Thought: OSHA's Top 10 violations haven't changed much year-over-year, which means the solutions are well-known. The difference between compliance and citations comes down to consistent execution, thorough documentation, and genuine commitment to worker safety. Start with this checklist, prioritize your highest risks, and build a culture where safety comes first.