Top OSHA Violations (And How to Avoid Them)
By LSC EHS Consulting Services, LLC
If you’ve been in construction, manufacturing, or general industry long enough, you already know one truth—Occupational Safety and Health Administration doesn’t show up when things are going well. They show up when something went wrong… or when your program has gaps.
After 20 years in safety leadership, I’ve seen the same violations hit companies across Tennessee year after year. The frustrating part? Most of them are completely preventable.
Let’s break down the most common OSHA violations in Tennessee—and more importantly, how to avoid them before they cost you money, reputation, or someone’s life.
1. Fall Protection (Construction – 1926.501)
The #1 violation—every single year.
Falls remain the leading cause of death in construction. Whether it’s roofing, scaffolding, or unprotected edges, companies continue to underestimate the risk.
Why does it happen?
Lack of proper guardrails or fall arrest systems
Poor training or enforcement
“Quick job” mindset
How to avoid it:
Implement a 100% tie-off policy above 6 feet
Conduct routine site audits
Train employees on proper harness use and inspection
Hold supervisors accountable—not just workers
2. Hazard Communication (1910.1200)
If you have chemicals on-site, this applies to you.
Why does it happen?
Missing or outdated Safety Data Sheets (SDS)
Improper labeling
Employees are unaware of chemical hazards
How to avoid it:
Maintain a current SDS binder (or digital system)
Label every container—no exceptions
Conduct annual HazCom training
Use simple, clear language that employees actually understand
3. Ladders (1926.1053)
Ladder violations are everywhere—from job sites to warehouses.
Why does it happen?
Using the wrong ladder type
Damaged ladders are still in service
Improper setup (wrong angle, unstable base)
How to avoid it:
Train workers on the 4:1 rule
Inspect ladders daily
Remove damaged ladders immediately
Provide the right ladder for the job—not just what’s available
4. Scaffolding (1926.451)
Scaffolding violations can turn deadly fast if not properly managed.
Why does it happen?
Improper assembly
Missing guardrails
Lack of competent person oversight
How to avoid it:
Assign a trained “competent person.”
Inspect scaffolds before every shift
Ensure proper planking and guardrails
Never allow unauthorized modifications
5. Respiratory Protection (1910.134)
This one is often overlooked until it becomes a serious health issue.
Why does it happen?
No written respiratory program
Failure to conduct fit testing
Improper mask selection
How to avoid it:
Develop a written respiratory protection program
Conduct annual fit testing
Provide medical evaluations
Match PPE to the hazard—not convenience
6. Lockout/Tagout (1910.147)
One mistake here can be fatal.
Why does it happen?
Lack of energy control procedures
Employees bypassing protocols
Inadequate training
How to avoid it:
Create machine-specific LOTO procedures
Train and retrain authorized employees
Audit your program annually
Enforce zero tolerance for shortcuts
7. Powered Industrial Trucks (Forklifts) (1910.178)
Forklift incidents are a major issue in warehouses and job sites.
Why does it happen?
Uncertified operators
Lack of refresher training
Poor traffic management
How to avoid it:
Certify all operators properly
Conduct 3-year evaluations (or sooner if needed)
Establish clear travel lanes and signage
Enforce speed limits and seatbelt use
The Real Problem: Complacency
Most OSHA violations don’t happen because companies don’t care—they happen because safety becomes routine, and routine becomes complacency.
Strong safety programs don’t just exist on paper. They live in:
Daily jobsite behavior
Supervisor enforcement
Leadership commitment
How LSC EHS Consulting Services Helps You Stay Compliant
At LSC EHS Consulting Services, we don’t just “check the box.” We build safety systems that actually work in the field.
We help businesses:
Identify hidden compliance gaps
Develop OSHA-compliant programs
Train teams in real-world safety practices
Prepare for and respond to OSHA inspections
