Ep. 574 OSHA Releases the Top 10 Most Frequently Cited Safety Violations for FY 2025

Rancho Mesa’s Alyssa Burley and Client Technology Specialist, Brenda Colby sit down to discuss OSHA’s top 10 most frequently cited safety violations for fiscal year 2025.

Show Notes: ⁠⁠⁠⁠Subscribe to Rancho Mesa's Newsletter⁠⁠⁠⁠

Host: ⁠⁠⁠⁠Alyssa Burley

Guest: ⁠⁠⁠⁠Brenda Colby

Editor: Jadyn Brandt

Music: "Home" by JHS Pedals, “Breaking News Intro” by nem0production

© Copyright 2025. Rancho Mesa Insurance Services, Inc. All rights reserved.

Transcript

Alyssa Burley: You're listening to Rancho Mesa’s StudioOne podcast, where each week we break down complex insurance and safety topics to help your business thrive. I'm your host, Alyssa Burley, and I'm joined by Brenda Colby, Client Technology Specialist with Rancho Mesa. And we're going to discuss OSHA's top 10 most frequently cited safety violations for fiscal year 2025. Brenda, welcome to the show.

Brenda Colby: Hi, Alyssa, happy to be here.

AB: Now, OSHA's preliminary data was released at the NSC Safety Congress and Expo, and we're counting them down from number 10 to number one and talking about what employers can do to stay compliant and keep their workers safe.

So we're kicking off our list at number 10, Machine Guarding. Brenda, why does this continue to show up on OSHA's radar?

BC: Good question. So machine guarding violations usually happen when employees are exposed to moving parts, points of operation, or flying debris. OSHA requires at least one method of guarding to protect workers from hazards like rotating parts, sparks, or nip points. Missing or inadequate guards put in place at serious risk for amputations and other injuries.

AB: Yeah, and I know that this one is absolutely preventable. And I know that some people think they'll just remove the guard and they'll just be extra careful, but that doesn't really work. So it is important to ensure all machines are properly guarded, guards are maintained, and never removed or bypassed.

Okay, so number nine is personal, protective, and life-saving equipment, specifically for eye and face protection. What's going on here?

BC: Well we are seeing that employers often fail to provide appropriate PPE, or they provide it but do not enforce its use. Workers exposed to debris, chemicals, or intense light must have proper eye and face protection and they need to wear it consistently.

AB: Yes, absolutely. So what's the simplest fix for this?

BC: Provide the right PPE, train employees on when and how to use it, and enforce compliance.

But to continue to our top 10 list, coming in at number eight, powered industrial trucks, including forklifts. This category covers improper operation, lack of training, poor maintenance, and unsafe modifications. OSHA requires operators to be trained and evaluated and trucks must be properly maintained.

AB: Yes, and forklift accidents can be severe or even fatal. And training and regular inspections make a huge difference. And our clients can use SafetyOne to perform and document both training and the regular inspections.

All right. So number seven is scaffolding. What's the biggest issue here?

BC: Well, the biggest issue is improper construction, overloading or lack of guardrails. Employers are responsible for ensuring scaffolds are built correctly, inspected regularly, and used within their capacity limits. If scaffoldling isn't built or used properly, fall risks skyrocket. And when injuries do occur, these type of claims can also be costly.

AB: Good point. And at number six, we have fall protection training requirements. Brenda, how is this different from general fall protection?

BC: So this type of citation focuses on training. Employers must train employees who work at heights on fall hazards, proper use of equipment, limitations of systems, and their role in the fall protection plan.

AB: Okay, so proper equipment alone isn't enough.

BC: No, it's not. And without training, even the best equipment won't keep workers safe. Now, number five is respiratory protection. Violations can often occur when employers don't provide medical evaluations, fit testing, or proper training. Any workplace with dust, fumes, or airborne hazards requires a compliant respiratory protection program.

AB: So what's the risk if respiratory protection isn't addressed?

BC: Long-term health issues, serious illness, and of course, preventable OSHA citations. So number four on the list is control of hazardous energy, better known as lockout/tagout. And this violation happens when machines aren't properly shut down and isolated during maintenance or servicing. Employers must have clear procedures, train employees, and regularly review their lockout/tagout programs because uncontrolled energy can lead to catastrophic injuries or fatalities in seconds.

AB: Yes, that is definitely a serious one. Okay, coming in at number three, on the list is ladders. What can you tell us about these types of citations and best practices for dealing with ladders?

BC: Well, common issues include using damaged ladders, setting them up incorrectly, or using them for unintended purposes. Ladders seem simple, but misuse leads to serious falls. As for best practices, inspect ladders regularly, train employees, and use the right ladder for the job.

AB: Yes, and we have a ladder safety course our clients can take in person or online. Now, hazard communication citations, we're the second most common type of citation this past year. So what does that entail?

BC: This one involves chemical safety. Employers must maintain proper labels, safety data sheets, and training. And when employees don't understand the chemicals they're working with, the risk of injury increases dramatically.

AB: Yes, communication really is the key here.

BC: Absolutely. Clear information prevents accidents and citations.

AB: Okay, so What was the number one most common citation in 2025?

BC: For the 15th year in a row, fall protection—general requirements top the list. Falls remain the leading cause of serious injuries and fatalities. Violations often involve missing guardrails, safety nets, or personal fall arrest systems. OSHA expects employers to identify fall hazards and provide appropriate protection.

AB: So why do we keep seeing this at the top of the list?

BC: Because fall hazers are common at a lot of job sites, and when they're not addressed, the consequences are severe.

AB: Okay, well, there you have it, the top 10 OSHA violations of 2025. Some of them are not surprising, like the last one. But addressing these areas is one of the best ways employers can reduce injuries, improve compliance, and protect their workforce.

And Rancho Mesa's extensive library of safety trainings and toolbox talks are available through the SafetyOne platform. And it's an excellent resource to help keep safety top of mind. So Brenda, if listeners have questions about using our SafetyOne platform or our other resources for safety training, what's the best way to get in contact with you?

BC: As always, clients can contact me at bcolby@ranchomesa.com or they can call me directly at 619-486-6562.

AB: All right. Well, Brenda, thank you for joining me in StudioOne.

BC: Thanks for having me.

AB: Thanks for tuning in to our latest episode produced by StudioOne. If you enjoyed what you heard, please share this episode and subscribe. For more insights like this, visit us at RanchoMesa.com and subscribe to our weekly newsletter.