Every year, thousands of businesses in California face costly fines, legal challenges, and reputational damage due to OSHA violations. The most common issues are often preventable—with the right training, safety protocols, and internal accountability. Whether you’re a small business or a large manufacturing facility, understanding the top OSHA violations can help you avoid major setbacks.

At ROI Safety Services, we specialize in helping companies throughout California maintain OSHA compliance through on-site training, audits, and employee education. In this post, we break down the most cited violations and how your organization can avoid them.

Why OSHA Compliance Matters

OSHA—the Occupational Safety and Health Administration—exists to protect workers by enforcing safety standards in the workplace. Failing to comply with OSHA regulations can result in:

Heavy fines (sometimes in the tens or hundreds of thousands)
Legal liability for accidents or injuries
Workers’ compensation claims
Shutdowns or stop-work orders
Loss of insurance coverage or increased premiums

Most violations stem from a lack of proper training, inconsistent safety protocols, or outdated procedures. That’s why a proactive, ongoing compliance strategy is essential—and ROI Safety Services offers a Safety Training Subscription designed to help California businesses stay protected year-round.

The Top 7 OSHA Violations in California

1. Fall Protection (Construction and General Industry)

Falls remain the leading cause of fatalities in construction. OSHA mandates proper use of guardrails, harnesses, safety nets, and training for working at height.

Avoid It: Conduct fall hazard assessments, ensure PPE is in place, and provide regular fall protection training. Our on-site safety training ensures your team understands how to prevent fall-related incidents in real-world scenarios.

2. Hazard Communication (HAZCOM)

OSHA’s HAZCOM standard ensures workers know about the chemicals they’re exposed to. Violations typically involve poor labeling, missing Safety Data Sheets (SDS), and lack of employee training.

Avoid It: Maintain up-to-date chemical inventories, ensure all containers are labeled, and train employees on chemical hazards and emergency response procedures.

3. Forklift/Powered Industrial Trucks

Improper forklift operation or certification is one of the most frequently cited OSHA violations. These incidents often result in injuries, property damage, or fatalities.

Avoid It: Certify all forklift operators through a program like our Forklift Train the Trainer course. This enables in-house trainers to keep certifications current and compliant.

4. Lockout/Tagout (LOTO)

LOTO violations occur when companies fail to control hazardous energy sources during maintenance or repair work, putting employees at serious risk.

Avoid It: Establish and enforce a written LOTO program. Train workers on proper shutdown and startup procedures. Conduct regular audits and retraining sessions.

5. Respiratory Protection

Many workers in industrial environments are exposed to dust, fumes, or airborne chemicals. Failing to provide or properly use respiratory protection can lead to serious health consequences—and OSHA penalties.

Avoid It: Conduct air quality assessments, provide fit-tested respirators, and develop a written respiratory protection plan. Include respiratory training as part of your routine on-site training.

6. Machine Guarding

Machine guarding violations happen when machinery lacks proper barriers or fails to protect workers from moving parts.

Avoid It: Install guards on all machinery, train workers on safe operating procedures, and inspect equipment regularly. Reinforce training quarterly or whenever equipment changes.

7. Electrical Wiring and Systems

Improper wiring, exposed conductors, and lack of grounding are common OSHA citations across multiple industries.

Avoid It: Schedule regular electrical system inspections and ensure all maintenance staff are properly trained in OSHA’s electrical safety standards.

How ROI Safety Services Can Help

Avoiding OSHA violations requires more than one-time training. It’s about building a safety culture supported by expertise, documentation, and follow-through.

At ROI Safety Services, we offer:

Customized on-site safety training
Train the Trainer programs to scale compliance internally
Monthly and annual Safety Training Subscriptions to keep you OSHA-ready
Detailed workplace safety audits and hazard assessments
Support across all major California training locations

Whether you’re in construction, manufacturing, warehousing, or logistics, we ensure your business doesn’t fall into the same traps that lead to citations and injuries.

OSHA Violations and Your Bottom Line

The cost of a single OSHA fine can reach $16,000 or more per violation—and penalties increase with repeat offenses. Beyond that, you also face:

Increased insurance premiums
Downtime and lost productivity
Damaged reputation with customers and stakeholders
Higher employee turnover

By investing in proactive training and compliance management, you’re protecting both your people and your profits.

Are You at Risk?

If you’re unsure whether your current safety practices are up to OSHA standards, we can help. ROI Safety Services offers free consultations and OSHA readiness assessments to give you peace of mind.

Visit our About Us page to learn more about our mission and team.

Don’t Let OSHA Catch You Off Guard

Compliance isn’t optional—and when it comes to OSHA, ignorance is not a defense. Get ahead of violations with our trusted, hands-on approach to safety training.

✅ Schedule a free compliance consultation
✅ Sign up for a Training Subscription
✅ Equip your team with certified Train the Trainer programs
✅ View our training locations and see where we serve you best

Let ROI Safety Services help you avoid OSHA violations—and build a safer workplace from the inside out.

Top OSHA Violations in California and How to Avoid Them