The FY 2024 List Is Out

OSHA has released its fiscal year 2024 list of the ten most frequently cited workplace safety violations, covering inspections from October 1, 2023 through September 30, 2024. The list is a reliable barometer of where American workplaces continue to fall short — and for the chemical industry, several of the top entries hit close to home.

The Top 10 Violations

1. Fall Protection (29 CFR 1926.501) — The perennial #1 violation, dominating construction and industrial sites
2. Hazard Communication (29 CFR 1910.1200) — Directly relevant to chemical handling: improper labeling, missing SDS, and inadequate employee training
3. Ladders (29 CFR 1926.1053) — Improper setup, missing inspections, and exceeding load ratings
4. Respiratory Protection (29 CFR 1910.134) — Critical for workers exposed to chemical vapors, dusts, and fumes
5. Lockout/Tagout (29 CFR 1910.147) — Failure to control hazardous energy during equipment maintenance
6. Powered Industrial Trucks (29 CFR 1910.178) — Forklift safety in warehouses and chemical storage facilities
7. Fall Protection Training (29 CFR 1926.503) — Having equipment isn't enough; workers need documented training
8. Scaffolding (29 CFR 1926.451) — Structural deficiencies and missing guardrails
9. Eye and Face Protection (29 CFR 1926.102) — 1,814 citations issued in FY 2024 alone
10. Machine Guarding (29 CFR 1910.212) — Missing or bypassed guards on production equipment

What This Means for Chemical Operations

Three entries on this list are especially relevant to anyone who handles, stores, or ships chemicals:

Hazard Communication (#2)

The HazCom standard requires employers to maintain a written hazard communication program, keep SDSs accessible for every hazardous chemical on-site, and train employees on labeling and safe handling. Violations typically involve missing or outdated Safety Data Sheets, unlabeled secondary containers, and no documented training records.

Respiratory Protection (#4)

Facilities handling volatile solvents, acids, or fine powders must have a respiratory protection program that includes medical evaluations, fit testing, and proper respirator selection based on the specific chemical hazards present.

Eye and Face Protection (#9)

With 1,814 citations in a single fiscal year, this standard catches operations where chemical splash goggles, face shields, or safety glasses are required but not provided or not worn. Chemical splash injuries remain one of the most preventable workplace hazards.

Practical Steps to Stay Compliant

• Audit your SDS binder — Confirm every chemical on-site has a current SDS and that employees know how to access them
• Review training records — HazCom, respiratory protection, and PPE training must be documented. If it's not written down, OSHA considers it not done
• Inspect PPE inventory — Check that goggles, face shields, respirators, and gloves match the hazards employees actually encounter
• Walk your facility — Look for unlabeled containers, blocked eyewash stations, and expired respiratory cartridges
• Update your written programs — HazCom plans, respiratory protection programs, and lockout/tagout procedures should reflect current operations, not last year's setup