In the United States, falls are one of the top causes of workplace injuries and fatalities each year. Despite clear guidelines from OSHA, it's common for employers covered by the Occupational Safety and Health Act to violate the agency's fall-protection standards, which are outlined in Title 29 of the U.S. Code of Regulations. These violations put workers at risk and expose businesses to costly penalties.

This article describes the most common OSHA fall-protection violations, explains why they occur and offers tips to help you stay in compliance. Learn more about these issues to create a safer workplace and protect your company from unintended legal and financial consequences.

Despite clear guidelines from OSHA, it's common for employers covered by the Occupational Safety and Health Act (meaning they are legally required to follow OSHA’s safety regulations) to violate the agency's fall-protection standards, which are outlined in Title 29 of the U.S. Code of Regulations. These violations put workers at risk and expose businesses to costly penalties.

1. Failure to Provide Fall Protection at Required Heights

If employees work at a regulated elevation, you must provide several types of fall protection. The regulated elevations are as follows:

• General industry: 4 feet
• Shipyards: 5 feet
• Construction industry: 6 feet

For example, if you employ construction workers who'll be walking on scaffolding outside the second story of a structure, you have to follow the fall-protection guidelines. Falls from heights are also common in agriculture and manufacturing, especially among employees who use mechanical equipment or rely on ladders to perform some of their duties.

It's critical to understand the fall-protection requirements, as OSHA has the authority to levy fines and other penalties for noncompliance. Using fall protection also prevents accidents that can drive up your company's insurance costs and damage its reputation.

Unfortunately, noncompliance is common. Some business owners are simply unaware of the OSHA requirements, while others attempt to cut costs by requiring employees to work without fall-protection systems.

Skimping on fall protection can cost you in the long run, however, as OSHA levies fines of up to $16,550 per violation. If you don't address the violation by the deadline, known as the abatement date, OSHA can fine your company an additional $16,550 per day. The penalty for "willful" or repeated violations is a whopping $165,514.

2. Lack of Proper Guardrails and Handrails

OSHA's requirements for guardrails and handrails are outlined in 29 CFR 1910.29. Guardrails protect employees by creating a barrier along an unprotected walkway. For example, roofers need guardrails to prevent falls while they're walking along unfinished roof systems. Handrails and stair rails prevent falls on ramps and stairways.

If a guardrail system is required, it must rise at least 42 inches, plus or minus 3 inches, above the walking surface. Your guardrail system must also be able to withstand the force of at least 200 pounds. The minimum height and weight requirements ensure a guardrail system creates an effective barrier.

Handrails must be no less than 30 inches and no more than 38 inches high. OSHA changed its stair rail guidelines in 2017, so the height requirements depend on installation date:

• 30 inches high for stair rail systems installed prior to January 17, 2017
• 42 inches for stair rail systems installed on or after January 17, 2017
  

One of the most common compliance mistakes is failing to install required guardrails, handrails or stair rails. It's also a violation to have a rail system that doesn't meet OSHA's height requirements. In 2024, a construction laborer fell 10 feet from unprotected scaffolding, resulting in a fatal brain injury. OSHA cited the employer for a serious violation, highlighting the dangers of failing to install proper safety systems. Installing compliant rail systems prevents tragic accidents and protects employers against fines and other penalties.

3. Improper Use of Personal Fall Arrest Systems (PFAS)

A personal fall arrest system doesn't prevent falls, but it stops falls already in progress, reducing the risk of injuries. These systems typically have anchors, harnesses and other components to stop employees from falling to the ground. OSHA's guidelines for PFAS are covered in 29 CFR 1910.140. These are just a few of the requirements:

• Connectors must be made from forged, formed, or pressed steel or equivalent materials.
• Vertical lifelines must have a breaking strength of at least 5,000 pounds.
• A "qualified person" or "competent person" must inspect each vertical lifeline before an employee uses it.

Common PFAS violations include worn-out straps, failure to conduct equipment inspections and improper fit. It's also a violation to provide inadequate PFAS training — or no training at all. OSHA requires employers to provide training to anyone exposed to fall hazards. Among other topics, the training must cover the use and operation of PFAS.

4. Unsafe Ladder Usage and Lack of Fall Protection for Ladders

Covered employers must follow OSHA's ladder guidelines to the letter. These are just a few of the regulations in 29 CFR 1926.1053:

• A self-supporting ladder must be capable of supporting at least four times the maximum intended load.
• Rungs and steps must be no less than 10 and no more than 14 inches apart. This applies to fixed and portable ladders.
• When a ladder is in use, the rungs, steps, and cleats must be level and uniformly spaced.
• Fixed metal ladders made after March 15, 1991, must have slip-resistant material or receive some kind of treatment to prevent slipping.
  

Employees often ignore ladder safety protocols to save time or make their jobs easier, increasing the risk of injury. One way to prevent accidents is to use these products designed to improve ladder stability:

• Ladder-safety docks
• Ladder-safety arms
• Ladder-safety legs
• Fixed-ladder lifeline systems
  

5. Failure to Train Workers on Fall Protection

Covered employers must cover the following topics in their fall-protection training:

• Recognizing fall hazards
• Steps for minimizing the risk of hazards
• Procedures for setting up, maintaining and disassembling fall-protection systems
• The role of employees in maintaining safety
• OSHA fall-protection standards
• Safe use of guardrails, handrails and other protection devices
  

Many companies neglect this critical safety measure due to a lack of time or training personnel. However, this isn't a valid excuse for failing to comply with OSHA's training requirements. All new employees should receive training before they perform safety-sensitive duties. It's also helpful to provide annual training to ensure team members don't forget what they learned.

How Safety Rail Source Helps Companies Stay OSHA-Compliant

Safety Rail Source is committed to helping employers stay compliant and avoid costly penalties. We offer a variety of products designed to protect employees working at heights, including modular guardrails, safety gates, rooftop safety barriers and customized fall-protection systems. Our team members have specialized knowledge of the OSHA requirements, so we can also help you choose the right products for your workforce.

Protect Your Workforce and Avoid OSHA Violations

Fall-protection violations are extremely common, but they're also preventable, as long you engage in proper planning and use the right equipment. If you're covered by the Occupational Safety and Health Act, you're required to follow the OSHA guidelines on personal fall arrest systems, ladder safety, rail systems and fall-protection training.

Assess your current fall-protection protocols, and then reach out to Safety Rail Source to fulfill any unmet safety needs.