OSHA Violations Small Business Owners Must Fix Before Getting Cited

OSHA violations are not just a large manufacturing problem. Small businesses across retail, food service, healthcare, professional services, and office environments receive citations regularly — and the financial consequences are significant. As of 2024, serious OSHA violations carry penalties up to $16,550 per violation, and willful or repeat violations can reach $161,323 per citation.

Beyond the financial penalties, OSHA violations create workers’ compensation exposure, civil liability if an employee is injured in connection with an unaddressed hazard, and reputational risk in industries where safety record matters. Understanding the most common OSHA violations small businesses face is the first step to addressing them before an inspector identifies them for you.

OSHA publishes its annual list of the top 10 most frequently cited standards specifically to help employers self-identify and correct common hazards. For FY 2024, Hazard Communication remained the most cited general industry standard. Here are the five OSHA violations most likely to affect small businesses, what each standard requires, and exactly what to do to fix each one.

OSHA Violation #1: Hazard Communication Standard (29 CFR 1910.1200)

The Hazard Communication Standard is the most cited general industry OSHA violation year after year. It applies to every workplace that uses hazardous chemicals — and the definition of hazardous chemicals is broader than most employers realize. It includes not just industrial solvents and chemicals but common workplace products like cleaning agents, disinfectants, paints, adhesives, fuels, and aerosol sprays.

What the standard requires:

• A written hazard communication program that describes how your workplace identifies and communicates chemical hazards
• A Safety Data Sheet (SDS) for every hazardous chemical used or stored on site — accessible to employees during every shift, not locked in a manager’s office
• Proper labels on all chemical containers identifying the hazard and required precautions
• Documented employee training on the specific chemicals they may encounter, the health hazards they present, and the protective measures required

Why businesses get cited: The most common failure is not the absence of awareness that the standard exists — it is the absence of a written program and accessible SDS sheets. Employers often have some chemicals on site without maintaining current SDS sheets, or store SDS documentation in a location employees cannot access without asking a supervisor.

How to fix OSHA violations related to hazard communication: Conduct a chemical inventory of everything used in your workplace. Request SDS sheets from your suppliers or chemical manufacturers for each product — most are available through manufacturer websites. Store SDS sheets in a binder or digital system that employees can access independently at any time. Write a brief hazard communication program (OSHA provides guidance and templates). Document employee training with dated, signed acknowledgments.

OSHA Violation #2: Respiratory Protection (29 CFR 1910.134)

OSHA’s Respiratory Protection Standard consistently ranks among the top OSHA violations in general industry. The standard applies whenever employees use respirators — and this includes situations where use is voluntary, not just required. Many small business owners are surprised to learn that simply providing dust masks or N95 respirators without implementing a formal written program constitutes an OSHA violation.

What the standard requires:

• A written respiratory protection program describing when respirators are required, which types are appropriate for which hazards, and how the program is administered
• Medical evaluations to confirm that employees assigned to wear respirators are physically able to do so safely — conducted by or under the supervision of a licensed physician
• Fit testing for tight-fitting respirators (N95s, half-face respirators, full-face respirators) — both before initial use and annually thereafter
• Training on the proper use, maintenance, storage, and limitations of the respirators being used
• Procedures for cleaning, disinfecting, storing, and replacing respirators

Why businesses get cited: The respiratory protection OSHA violations most commonly involve employers who provide respirators for “light duty” use without establishing any program — often because they underestimate the regulatory obligations triggered by providing any respiratory protection at all.

How to fix it: Start with a written program. OSHA provides a sample respiratory protection program that covers the required elements. If employees use any respirators — even dust masks used voluntarily — ensure you have a program in place and have completed the medical evaluation step.

OSHA Violation #3: Control of Hazardous Energy — Lockout/Tagout (29 CFR 1910.147)

The Control of Hazardous Energy standard, commonly known as lockout/tagout, applies to any workplace where employees service or perform maintenance on equipment that could unexpectedly start up, energize, or release stored energy during the work. This standard is more broadly applicable than most small business owners realize.

Equipment that triggers lockout/tagout requirements includes: industrial machinery with moving parts, commercial kitchen equipment such as slicers and mixers, electrical panels and switchboards that employees work on, HVAC systems requiring maintenance, compressed air systems, and hydraulic equipment. If employees clean, unclog, lubricate, or perform any maintenance on machinery — not just formal “repair” — the standard may apply.

What the standard requires:

• A written energy control program that establishes the scope, purpose, and rules for controlling hazardous energy
• Documented energy control procedures for each specific piece of equipment covered — including the type and magnitude of hazardous energy, the steps to isolate and lock out the equipment, and the steps to verify isolation before work begins
• Training for all employees who perform servicing and maintenance covered by the program, plus awareness training for employees who work in areas where lockout/tagout is used
• Annual periodic inspections of energy control procedures to confirm they are being followed correctly

How to fix lockout/tagout OSHA violations: Start with an equipment inventory. Identify every piece of equipment in your facility that requires maintenance or servicing where unexpected energization would create a hazard. Develop equipment-specific procedures (OSHA provides templates) and implement training for all affected employees.

OSHA Violation #4: Electrical General Requirements (29 CFR 1910.303)

Electrical OSHA violations appear consistently in the top 10 most cited standards and are among the most dangerous workplace hazards. Unlike some other OSHA standards that require formal programs and documentation, many electrical violations are immediately visible — and immediately fixable — with a basic walk-through of your facility.

Common electrical OSHA violations in small businesses:

• Blocked electrical panel access: OSHA requires 36 inches of clear working space in front of all electrical panels at all times. Storing boxes, equipment, or any other materials in front of electrical panels is a citation waiting to happen — and an immediate hazard.
• Extension cords as permanent wiring: Extension cords are designed for temporary use, not permanent installation. Using extension cords as a substitute for permanent wiring is an OSHA violation and a fire hazard.
• Missing outlet covers and junction box covers: Any electrical outlet, junction box, or panel without a proper cover presents both a shock hazard and an OSHA violation. Walk your facility and identify every uncovered electrical component.
• Damaged wiring: Frayed, cracked, or damaged electrical cords and wiring anywhere in the facility — whether on equipment or in walls — must be replaced immediately.
• Overloaded circuits: Plugging multiple high-draw devices into a single circuit via power strips or multi-plug adapters without regard for circuit capacity creates a fire and shock hazard.

How to fix electrical OSHA violations: Conduct a systematic walk-through specifically looking at electrical components. Clear all materials from in front of electrical panels. Replace damaged cords. Install missing covers. Evaluate whether any areas rely on extension cords for permanent power needs and have a licensed electrician add permanent outlets if necessary.

OSHA Violation #5: Eye and Face Protection (29 CFR 1910.133)

OSHA reports that eye injuries cost businesses more than $300 million annually in lost production time, medical expenses, and workers’ compensation claims. An estimated 2,000 workers suffer job-related eye injuries requiring medical treatment every day in the United States. Most of these injuries are preventable with proper PPE.

The Eye and Face Protection Standard requires employers to assess the hazards of each job task, select appropriate eye and face protection for identified hazards, provide that protection to employees at no cost, and ensure it is used consistently. It applies whenever work creates a hazard of injury to eyes or face from flying particles, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation.

What the standard requires:

• A written hazard assessment identifying tasks that create eye or face hazards
• Selection of appropriate protection — safety glasses, chemical splash goggles, face shields, or welding helmets depending on the hazard type
• Provision of selected PPE to all employees performing covered tasks at no cost to the employee
• Training on when PPE is required, what type is required, how to properly don and doff it, the limitations of the equipment, and how to maintain it
• Documentation of the hazard assessment and employee training

Why businesses get cited: The most common failure is not a complete absence of eye protection — it is inconsistent use with no enforcement, and no documentation that a hazard assessment was conducted or that employees were trained. OSHA inspectors will ask for your hazard assessment documentation and training records, not just look to see if safety glasses are available.

How to Conduct an OSHA Compliance Walk-Through for Your Small Business

The most efficient approach to addressing OSHA violations in a small business is a systematic, documented self-inspection. Walk through your facility specifically looking for each of the five categories above, plus any industry-specific standards that apply to your type of business.

Document what you find — both what is compliant and what needs correction. Create a written remediation plan for any issues identified, with assigned responsibility and target completion dates. Address immediate life-safety hazards the same day. Schedule longer-term fixes within 30 to 90 days depending on complexity.

This documentation matters beyond just having the fixes in place. OSHA’s small business assistance program notes that employers who can demonstrate a good-faith, documented compliance effort receive more favorable treatment in enforcement situations than employers who have no program at all. Your written records of identifying and addressing hazards are evidence of exactly that good-faith effort.

For an OSHA small business compliance checklist covering all five of these standards — printable and ready to use as your walk-through tool — visit the Greenline Advisory shop.

Sources: OSHA: Eye and Face Protection