OSHA’s Top Violations for 2025
Will the top spot change?
Ensuring workplace safety is an ongoing challenge, especially in fast-paced manufacturing and warehousing operations. Every year, the OSHA publishes its list of the most frequently cited workplace safety violations, providing a snapshot of the most pressing hazards that can lead to injuries and serious fines.
While the list results do not have many changes from year to year, it is important to review annually. Comparing your safety processes and training to what is included can help to create a more robust system that can save lives and protect what matters.
As we do every year, let us take a deep dive into the top 10 and see what is moving and shaking for 2025.
10. Machine Guarding (1910.212)
FY 2025 Violations: 1,239
FY 2024 Violations: 1,541
While citations for machine guarding have dropped, it remains a critical focal point. This is particularly true in manufacturing facilities with heavy machinery and distribution centers where automated equipment is prevalent. Improper or missing guards can expose workers to rotating parts, pinch points, and sparks. Even a minor oversight on a conveyor system or robotics cell can result in catastrophic injury.
9. Eye and Face Protection (1926.102)
FY 2025 Violations: 1,665
FY 2024 Violations: 1,814
Holding steady in the bottom half of the list, eye and face protection remains a persistent risk. Most violations occur due to employees not wearing required PPE or because the equipment provided is not suitable for the specific hazards present, such as flying particles or chemical splashes.
8. Powered Industrial Trucks (1910.178)
FY 2025 Violations: 1,826
FY 2024 Violations: 1,931
Forklifts and other powered industrial trucks are the backbone of the modern warehouse, but they are also among the most dangerous tools on the floor. Most citations in this category involve inadequate operator training, lack of refresher evaluations, or operating unsafe equipment. Safety automation, like AisleCop or motion sensors, can help mitigate these risks, but they cannot replace a solid training foundation.
7. Scaffolding (1926.451)
FY 2025 Violations: 1,905
FY 2024 Violations: 2,058
Scaffolding violations are frequent during facility expansions or maintenance projects. Issues often include improper access, lack of guardrails, or failing to ensure the structure is on a stable foundation. Even if you use third party contractors for these projects, the safety of the environment remains a shared responsibility.
6. Fall Protection – Training Requirements (1926.503)
FY 2025 Violations: 1,907
FY 2024 Violations: 2,020
It is not enough to provide fall protection equipment; you must ensure employees know how to use it. This standard focuses on the failure to provide a training program for each employee who might be exposed to fall hazards. If your training records are not up to date or your staff cannot demonstrate proper harness fit, you are at risk for this citation.
5. Respiratory Protection (1910.134)
FY 2025 Violations: 1,953
FY 2024 Violations: 2,095
Respiratory protection remains a top five concern. Common issues include the lack of a written respiratory program, incomplete fit-testing, and missing medical evaluations. This is especially relevant in operations with paint booths, welding, or chemical handling.
4. Lockout/Tagout (1910.147)
FY 2025 Violations: 2,177
FY 2024 Violations: 2,443
The control of hazardous energy is vital for maintenance and repair work. Violations often stem from failing to establish a site-specific program or failing to train “affected” employees who work around the equipment being serviced. As facilities become more automated, the complexity of lockout/tagout procedures increases.
3. Ladders (1926.1053)
FY 2025 Violations: 2,405
FY 2024 Violations: 2,573
Ladders remain a top three OSHA citation. Warehouses see frequent use of portable ladders for rack access and overhead maintenance. Potential for misuse or using damaged equipment is high. Proper inspection protocols and choosing the right ladder for the job are essential.
2. Hazard Communication (1910.1200)
FY 2025 Violations: 2,546
FY 2024 Violations: 2,888
Consistently near the top, HazCom centers on identifying chemicals, maintaining Safety Data Sheets (SDSs), and training employees. Even if you do not consider your facility a chemical plant, cleaning supplies and forklift fuels fall under this umbrella.
1. Fall Protection – General Requirements (1926.501)
FY 2025 Violations: 5,914
FY 2024 Violations: 6,307
For the 15th consecutive year, Fall Protection takes the #1 spot. While the total number of violations decreased slightly, it still towers above the rest. This reflects both OSHA’s enforcement priority and the persistent challenges of preventing fall hazards on loading docks, mezzanines, and pick modules.
The Takeaway
While the total number of citations across the top 10 has trended downward in 2025, the order remains remarkably consistent. Reviewing this list is a great time to walk your floor. Look at your dock edges, check your forklift training logs, and ensure your machine guards are actually in place. A proactive approach today is much less expensive than a citation or an injury tomorrow.
*Disclaimer: This post is intended for general informational purposes and does not constitute legal or compliance advice. For specific guidance tailored to your site, consult with a qualified safety professional or contact OSHA directly.
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Evan Fleishacker is a Marketing Strategist at Cisco-Eagle. You can find him on LinkedIn at linkedin.com/in/evanf