In this blog, we share the Top 10 OSHA Violations of 2025 — What They Mean for Forklift Employers (and How T&J Safety & Training Can Help). Every fall, OSHA’s “Top 10 Most Frequently Cited Violations” offers a roadmap to the hazards that trip up the most employers — and often the ones that lead to serious injury, costly fines, or worse. The 2025 list is out — and while many of the top hazards aren’t directly about forklifts, several absolutely hit workplaces like yours that rely on powered industrial trucks. (Bene-Care)
At T&J, we believe that sharing this data — and using it to guide robust safety training — is one of the best things we can do to help our clients stay compliant, protect their workers, and avoid costly shutdowns or liability. Below is a breakdown of the top 10, why they matter, and how targeted forklift- and warehouse-safety training can make the difference.
The 2025 Top 10 OSHA Violations
| Rank | Violation / Standard | 2025 Citation Count | What It Means for Employers |
| 1 | Fall Protection – General Requirements (1926.501) | 5,914 (ICC Compliance Center Inc – USA) | Fall hazards — especially in construction/warehouse zones with elevated platforms, mezzanines, loading docks. If your facility includes elevated storage, catwalks, or workers climbing ladders or standing on platforms, this is a major risk. |
| 2 | Hazard Communication (1910.1200) | 2,546 (ICC Compliance Center Inc – USA) | Mishandling or mis-labeling of hazardous materials (chemicals, cleaning agents, fuels). Even warehouses with forklift activity often store batteries, solvents, or maintenance chemicals — so proper labeling, SDS access, and training matter. |
| 3 | Ladders (1926.1053) | 2,405 (Bene-Care) | Unsafe ladder use — e.g., unstable, damaged, or misused ladders when retrieving inventory or doing maintenance. Warehouses sometimes rely on ladders for quick access; mistakes plus forklift traffic = accidents. |
| 4 | Lockout/Tagout – Control of Hazardous Energy (1910.147) | 2,177 (ICC Compliance Center Inc – USA) | Machines or equipment that are serviced without proper lockout/tagout procedures. Even if not forklift-specific, it’s vital for any powered equipment in the facility. |
| 5 | Respiratory Protection (1910.134) | 1,953 (PTZWSR Attorneys) | Exposure to dusts, fumes, or other airborne hazards — maybe from warehouse operations, stored chemicals, or maintenance tasks. Proper respirators + fit-testing + training required. |
| 6 | Fall Protection – Training Requirements (1926.503) | 1,907 (Bene-Care) | Even when fall protection systems exist, failure to train workers properly on their use leads to citations. Training is just as important as equipment. |
| 7 | Scaffolding (1926.451) | 1,905 (PTZWSR Attorneys) | For facilities using scaffolds (e.g., for maintenance, installing lighting or signage), incorrect scaffold assembly or use remains a major risk — especially when combined with forklift or warehouse traffic. |
| 8 | Powered Industrial Trucks – Forklifts (1910.178) | 1,826 (Bene-Care) | Directly relevant to you: forklift training, certification, safe operation — this remains one of the top-cited violations. Often tied to lack of proper training/certification, unsafe driving, or unsafe workplace layout. (lion.com) |
| 9 | Personal Protective & Life-Saving Equipment – Eye and Face Protection (1926.102) | 1,665 (Bulwark Safety Systems) | Situations where debris, chemicals or flying particles occur (e.g., loading, maintenance, cleaning). Warehouses are noisy, busy — PPE must be enforced. |
| 10 | Machine Guarding (1910.212) | 1,239 (sbcacomponents.com) | Machinery — conveyors, pallet wrappers, forklifts with attachments — must have guards to prevent crushing, amputation, or entanglement hazards. |
What This Means for Forklift–Heavy Facilities 📦🚧
- The fact that “Powered Industrial Trucks (Forklifts)” remains firmly in the Top 10 highlights a recurring problem: lack of consistent training, certification, and reinforcement of safe practices. (lion.com)
- But risk doesn’t come only from forklifts. Your facility likely involves ladders, shelving, maybe mezzanines or loading docks — so fall protection, ladder safety, and PPE compliance are probably already part of your daily operations.
- Many of these standards overlap — e.g., a pallet retrieval might involve a forklift + worker on a ladder + warehouse chemicals. If any one of those is out of compliance, you’re exposed.
- Cites happen because of systemic gaps — not always blatant “safety violations,” but often lack of training, complacency, or missing documentation (e.g., training records, PPE logs, hazard communication signage).
That’s exactly why integrated safety training — not just forklift-driving courses — works best.
How T&J Safety & Training Can Help You Stay Off the 2026 List
At T&J, we offer tailored training and safety-compliance services designed to address the most cited OSHA problems — especially for forklift-heavy workplaces. Here’s how we help:
- Comprehensive Forklift Certification & Refresher Training: We ensure your operators meet OSHA’s powered-industrial-truck requirements (1910.178), including safe operation, pre-shift inspection, load handling, pedestrian awareness, and re-evaluation/refresher training, particularly after incidents or observed unsafe practices.
- Warehouse Safety Audits: Our team can perform mock OSHA inspections — checking for fall protection hazards, proper ladder and scaffold usage, machine guarding, PPE compliance, and hazard communication procedures.
- Full-Facility Safety Training Programs: Beyond forklifts: we offer PPE training (eye/face, respirators if needed), hazard-communication awareness, lockout/tagout procedures, ladder & scaffolding safety, and fall protection best practices.
- Documentation & Compliance Support: We help you build and maintain records (training logs, inspection checklists, hazard communication materials) — often the difference between compliance and a citation during an OSHA visit.
- Customized Training for Your Layout & Operations: No two facilities are the same. We tailor training to your warehouse layout, forklift traffic patterns, storage practices, and unique hazards — maximizing relevance and effectiveness.
Final Thoughts — Why This Matters Now
OSHA’s 2025 report shows that despite years of awareness, many of the same hazards keep recurring. (Unland) That’s not just a compliance problem — it’s a risk to your workers’ lives, and to your business’s bottom line.
Because you run a forklift-heavy operation, your company is in a position where even “small” oversights (a forklift operator who never got proper refresher training, a missing Safety Data Sheet for a cleaning solvent, or a poorly maintained ladder) can lead to serious incidents or costly citations.
Investing in a robust, ongoing safety program isn’t optional — it’s essential. At T&J, we’re ready to help you build one that actually works.
Why Choose Thompson & Johnson for Forklift Operator Safety Training?
At Thompson & Johnson, our certified instructors bring real-world experience to every class. We offer both on-site training at your facility and in-branch sessions at any of our four locations across New York State: Syracuse, Binghamton, Horseheads and Schenectady.
✅Our program helps your business:
✅Stay OSHA compliant
✅Reduce workplace accidents
✅Lower equipment repair costs
✅Boost productivity and confidence
Schedule Your Forklift Safety Training
Ensure your team is trained, certified, and safe on the job. Contact our Safety Training Department today to schedule your next forklift operator class.
📞Call: (800) 589-5558
📧Email: training@thompsonandjohnson.com
🌐Learn more: https://thompsonandjohnson.com/our-services/training/
