OSHA General Industry Standards (29 CFR Part 1910)

Exit routes must be permanent, unobstructed, and free of explosive or flammable materials. Minimum 2 exit routes required (positioned so a single incident cannot block both); minimum ceiling height 7'6\" and width 28\". Exit signs must be illuminated to at least 5 foot-candles with letters minimum 6\" high. Routes must be lit to normal vision at all times.

• Exit route inspection checklist with dates (monthly recommended)
• Photographic evidence of illuminated exit signs and directional signs
• Floor plans confirming minimum two separated exit routes
• Foot-candle measurement records for exit route lighting
• Deficiency correction log

• Exit routes obstructed by stored materials (most common OSHA citation)
• Exit signs not illuminated during power outages (no backup power)
• Single exit route relied on for small facilities without documentation

Employers must maintain a written emergency action plan covering: emergency reporting procedures, evacuation routes and procedures with exit assignments, procedures for employees remaining for critical operations, employee accountability post-evacuation, rescue and medical duty assignments, and a named contact for plan questions. Employees must be trained upon initial employment, when duties change, and when the plan changes.

• Written Emergency Action Plan (EAP) with all required elements
• Evacuation floor plans with primary and secondary routes marked
• Employee training records for EAP (initial and refresher)
• Drill records with dates, participants, and debrief notes
• Named EAP coordinator with contact information posted

• EAP not updated after facility layout changes
• Employee accountability procedure missing or untested
• Contractors and visitors not included in evacuation planning

Employers must provide approved portable fire extinguishers with maximum travel distances of 75 feet for Class A and 50 feet for Class B hazards. Monthly visual inspections, annual maintenance with 1-year record retention, and hydrostatic testing per Table L-1 intervals are required. All employees receive familiarization training upon hire and annually; designated users receive specialized training.

• Monthly inspection tags/logs on each extinguisher
• Annual maintenance records retained for 1 year
• Hydrostatic test records per Table L-1 schedule
• Travel distance measurements confirming coverage
• Employee familiarization training records (annual)
• Designated user specialized training records

• Monthly inspection not documented (visual only, no record)
• Extinguisher type mismatched to hazard class
• Annual maintenance overdue
• Training records missing for newly hired employees

Automatic sprinkler systems must maintain 18-inch minimum clearance between sprinkler deflectors and stored materials, have water supply capable of design flow for 30+ minutes, conduct annual main drain flow tests and inspector's test valve operation every 2 years, and provide equivalent protection during any period the system is out of service.

• Annual main drain test records with flow rates
• Inspector's test valve records (biennial)
• Water supply documentation (flow test from hydrant or waterworks data)
• 18-inch clearance verification (storage height marks or inspection photos)
• Impairment notification records and temporary protection measures when system out of service

• 18-inch clearance violated by seasonal inventory buildup
• Main drain test not conducted annually
• No impairment procedure when system taken offline for maintenance

Employee alarm systems must be perceivable above ambient noise and light throughout the facility, produce distinctive signals for specific emergencies, and be tested every 2 months for non-supervised systems (different actuation device each test) or annually for supervised systems. Back-up alarm means must be in place when the primary system is out of service.

• Alarm system test records with dates and actuation devices used
• Audibility test records confirming perception above ambient levels throughout facility
• Back-up alarm procedure (runners, phone trees, air horns)
• Deficiency correction records
• Employee training records confirming distinctive signal recognition

• Bi-monthly tests conducted using the same actuation device each time
• No audibility test in high-noise production areas
• No documented back-up procedure when system is offline for maintenance

Employers must limit employee exposure to substances listed in OSHA Tables Z-1, Z-2, and Z-3 to specified PELs (8-hour TWA or ceiling values). For multiple substance exposures, cumulative formula applies. Engineering and administrative controls must be used first; respiratory protection is the last resort. Initial exposure monitoring is required to establish baseline for chemicals with PELs.

• Industrial hygiene exposure monitoring reports for regulated substances (initial + periodic)
• Monitoring method documentation (OSHA method or NIOSH method)
• Exposure results compared to PELs with compliance determination
• Engineering control descriptions (local exhaust ventilation design specs, enclosure measurements)
• Administrative control procedures (rotation schedules, work practice controls)
• Medical surveillance for substances requiring it (e.g., lead, cadmium)

• No initial exposure monitoring conducted for chemicals with OSHA PELs
• Monitoring conducted but results not compared to PELs
• Engineering controls present but effectiveness not verified by measurement

Employers must maintain a written HazCom program, Safety Data Sheets (16-section GHS format) accessible to employees during all work shifts for every hazardous chemical in the workplace, GHS-compliant labels on all containers, and training on the hazard classification system, SDS interpretation, chemical detection, protective measures, and emergency response.

• Written HazCom Program with SDS, labeling, and training procedures
• Complete chemical inventory cross-referenced to SDS library
• Confirmation SDSs are accessible on all shifts (physical binder + digital access)
• Label inspection records verifying all containers have GHS-compliant labels (product ID, pictogram, signal word, hazard/precautionary statements)
• Employee HazCom training records with chemical-specific content for their work area
• SDS review records for new chemicals before introduction

• SDSs not accessible on night shift
• Unlabeled secondary containers (transferred from original)
• Training generic rather than chemical-specific to employee's work area
• Contractor employers not informed of site chemical hazards in multi-employer workplaces

Flammable liquids are classified by flashpoint (Class IA-IC below 100°F; Class II 100-140°F; Class III above 140°F). Requirements cover storage tank design and venting, inside storage room construction (2-hour fire resistance, explosion-proof electrical, self-closing doors, mechanical ventilation), bonding and grounding for dispensing, and quantity limits for unprotected storage.

• Flammable liquid inventory with flash point classifications
• Inside storage room inspection records (fire-resistance rating, ventilation CFM, electrical classification)
• Tank vent inspection records
• Bonding and grounding equipment inspection log
• Quantity limits compliance check vs. allowable amounts without sprinkler protection

• Inside storage rooms lack self-closing door (propped open)
• Electrical equipment not rated for Class I Division 1 in flammable storage
• Quantities exceed limits without sprinkler compensation

Facilities with highly hazardous chemicals at or above threshold quantities (Appendix A to §1910.119) or 10,000+ lbs of flammable liquids/gases must implement 14 mandatory PSM elements: employee participation, process safety information, process hazard analysis, operating procedures, training, contractors, pre-startup safety review, mechanical integrity, hot work permits, management of change, incident investigation, emergency planning, compliance audits, and trade secrets.

• Written employee participation plan and consultation records
• Complete Process Safety Information package (P&IDs, safe operating limits, equipment data)
• PHA reports by methodology (HAZOP/What-If/FMEA) revalidated within 5 years
• Written operating procedures for all phases including emergency shutdown
• Training records with competency verification for all operators
• Contractor pre-qualification records and safety performance evaluations
• Pre-Startup Safety Review (PSSR) checklists for new/modified processes
• Mechanical integrity inspection and testing records with deficiency tracking

• PHA not revalidated on 5-year cycle
• Operating procedures not kept current with process changes (no MOC tie-in)
• Mechanical integrity inspection intervals exceed manufacturer recommendations without documented risk basis
• PSM audit conducted by internal team with conflict of interest

Employees involved in hazardous waste site cleanup, RCRA corrective actions, or emergency response to hazardous substance releases must receive role-based training: 40 hours classroom + 3 days supervised field for general site workers (8-hour annual refresher); 24 hours + 1 day field for occasional workers; additional 8 hours supervisor training for supervisors. Written site safety and health program required.

• Training completion certificates by role (40-hr, 24-hr, supervisor)
• Annual refresher training records
• Written Site Safety and Health Plan (SSHP)
• Medical surveillance records for exposed employees
• Decontamination procedure documentation
• Buddy system and emergency notification records for site entries

• Annual refresher not completed on calendar basis
• SSHP not updated between site characterization and active remediation phases
• Medical surveillance program not established for regularly exposed workers

Before any welding or cutting, combustible materials must be moved 35 feet or shielded with fire-resistant guards. Fire watch is required during operations and for 30 minutes after completion. Mechanical ventilation providing minimum 2,000 CFM per welder is required in spaces under 10,000 cubic feet or with ceilings below 16 feet. Special ventilation requirements apply for fumes from zinc, lead, beryllium, cadmium, and stainless steel.

• Hot work permit system with pre-job checklist
• Fire watch assignment records (during + 30 min post)
• Ventilation measurement records (CFM per welder) for confined/low-ceiling spaces
• Pre-job atmospheric testing records for confined space welding
• Training records for welders and fire watchers
• Inspection records for arc welding equipment (cable, electrode holders)

• Fire watch released immediately after work completion, not held 30 minutes
• No ventilation in spaces that trigger the size/height requirements
• Lead/beryllium/cadmium fume exposures not measured despite regulatory requirement

Employers must identify all permit-required confined spaces (containing serious physical hazard: hazardous atmosphere, engulfment, entrapment, or other recognized hazard), post danger signs, test atmospheric conditions before and during entry (in sequence: oxygen, combustibles, toxics), maintain an attendant outside at all times during entry, and retain entry permits for 1 year for annual program review.

• Written inventory of all permit-required confined spaces with hazard identification
• Danger signs posted at each permit space
• Completed entry permits (retained 1 year) with atmospheric test results and entry supervisor signature
• Calibration records for atmospheric monitoring equipment
• Attendant/entry supervisor training records
• Rescue service pre-entry capability verification (response time + equipment test)
• Annual program review using cancelled permits

• Spaces identified as non-permit without atmospheric testing basis
• Atmospheric testing sequence wrong (toxic before combustibles)
• Rescue capability assumed but never tested
• Cancelled permits not retained for annual review

Before servicing or maintenance where unexpected energization could cause injury, authorized employees must de-energize equipment, isolate all energy sources, and apply personal lockout/tagout devices. Written energy control procedures required for equipment with multiple energy sources. Annual periodic inspections required, conducted by an authorized employee other than the procedure user, with documented findings.

• Written energy control procedures per machine/equipment (or equipment group if identical)
• Annual periodic inspection records with inspector name, equipment ID, date, and employees involved
• Authorized and affected employee training records with competency verification
• Lockout/tagout device inventory (individually assigned, non-transferable)
• Multi-energy source isolation verification steps in each procedure

• Procedures outdated after equipment modifications
• Annual inspections not documented or not conducted by separate authorized employee
• Group lockout procedures not established for multi-person maintenance
• Tagout-only programs without documented equivalent protection justification

Employers must conduct and certify in writing a workplace hazard assessment to determine required PPE. The written certification must identify the workplace evaluated, the assessor, and the date. Selected PPE must be appropriate for the hazard, properly fit each employee, and be paid for by the employer (with limited exceptions for non-specialty items).

• Written PPE Hazard Assessment certifications with assessor signature and date per work area
• PPE selection matrix linking hazard to PPE type and standard (ANSI, ASTM)
• Employee PPE training records (initial + refresher)
• Fit documentation for respiratory protection and other fit-sensitive PPE
• PPE inspection and replacement records

• Hazard assessment completed but not certified in writing
• PPE selected by habit rather than documented hazard analysis
• Employer charging employees for required PPE

Employers requiring respirator use must establish a written program administered by a trained program administrator. Mandatory elements: medical evaluation using OSHA Appendix C questionnaire before first use; initial and annual fit testing for tight-fitting respirators; NIOSH-certified equipment used per certification; air-purifying respirator cartridge change schedule based on objective data; IDLH atmosphere procedures including standby rescue employee and communication system.

• Written Respiratory Protection Program with all required elements
• PLHCP medical evaluations and clearance letters for each respirator user
• Fit test records (qualitative or quantitative) with annual dates
• NIOSH approval numbers on all respirators in service
• Cartridge change schedule with objective data basis (OSHA SWPF or manufacturer SDS data)
• IDLH atmosphere procedures with standby rescue requirements

• Medical evaluation not completed before fit test
• Fit test records not retained
• Change schedule based on 'end of shift' rather than objective data
• IDLH procedures do not specify standby employee requirement

Employers must maintain OSHA Form 300 (Log), Form 300A (Annual Summary certified by a company executive and posted February 1 through April 30), and Form 301 (Incident Report). All records must be retained for 5 years following the end of the calendar year covered and updated during retention to reflect newly discovered cases.

• OSHA 300 Logs for current year and 5 prior years
• 300A Summaries with executive certification signature and dates
• Evidence of February 1 posting (photo, email confirmation)
• 301 Incident Reports for each recordable case
• Retention schedule or records management policy

• 300A not signed by qualifying executive (only site manager, not officer)
• Posting removed before April 30
• 5-year retention not maintained for prior years

Employers must report work-related fatalities to OSHA within 8 hours and work-related in-patient hospitalizations, amputations, or losses of an eye within 24 hours. Reports are made via OSHA's online portal, the 1-800-321-OSHA hotline, or the nearest OSHA Area Office.

• Written emergency reporting procedure identifying OSHA notification obligations
• OSHA confirmation receipts or call logs for any reported incidents
• Incident investigation reports cross-referencing OSHA report
• Training records showing supervisors know 8/24-hour reporting triggers
• Log of all incidents assessed for reportability (even if not reported)

• Supervisors unaware of 8-hour fatality reporting requirement
• In-patient hospitalization not reported because employee was later discharged
• No log of reportability assessments for near-miss events

Establishments with 100 or more employees in high-hazard NAICS codes must electronically submit OSHA 300 Log and 301 data annually via OSHA's Injury Tracking Application (ITA). Establishments with 20-249 employees in designated industries must submit the 300A Summary. Submissions are due March 2 each year.

• ITA submission confirmation email or screenshot for each required year
• NAICS code determination documentation
• Establishment size calculation for the prior calendar year
• Calendar reminders or procedure for March 2 deadline
• Data reconciliation between ITA submission and paper 300 Log

• Establishment incorrectly believes NAICS code is exempt
• Multi-site employers submit for wrong establishments
• March 2 deadline missed

Employers must record each work-related injury or illness resulting in death, days away from work, restricted work, job transfer, medical treatment beyond first aid, loss of consciousness, or a significant diagnosis by a licensed healthcare professional. Records must be entered on OSHA Form 300 within 7 calendar days.

• OSHA Form 300 Log with all recordable cases entered
• OSHA Form 301 Incident Reports for each case
• Written recording criteria procedure or decision flowchart
• Sample cases with documentation of recording decision rationale
• Evidence of 7-day entry timeliness

• Cases not recorded because employer misclassified medical treatment as first aid
• Restricted work cases recorded as 'other recordable' to avoid days-away count
• 7-day entry deadline missed