How to Prepare for an Inspection Focused on OSHA requirements for building material warehouses

If you operate a warehouse in the building materials industry, OSHA inspections aren’t a matter of if—they’re a matter of when. Warehouses are high-risk environments, and OSHA inspectors pay close attention to how employers handle everything from material storage and forklift safety to PPE compliance and emergency preparedness.

Being inspection-ready at all times isn’t just about avoiding fines—it’s about protecting your people, equipment, and reputation. Here’s how to prepare for an OSHA inspection and make sure your building material warehouse meets all the key regulatory standards.

• Understand the Most Common OSHA Violations in Warehouses

Knowing what OSHA is looking for helps you focus your preparation. In building material warehouses, common violations include:

Improper storage of heavy or unstable materials

Forklift operation without certification or proper maintenance

Blocked emergency exits or fire extinguishers

Missing or ineffective PPE usage

Incomplete hazard communication (HazCom) labeling and documentation

Poor housekeeping or cluttered walkways

Inadequate fall protection for elevated platforms or mezzanines

Build your inspection prep plan around correcting these common issues first.

• Conduct an Internal OSHA-Style Audit

Don’t wait for an official visit to find out what’s wrong. Perform your own walkthrough with the same level of scrutiny. During your internal audit, check:

Aisles are free of trip hazards and have proper clearance

Racks and shelves are stable and materials are stored safely

All powered industrial trucks (e.g., forklifts) are inspected daily

PPE stations are fully stocked and usage is enforced

Emergency exits are marked, lit, and unobstructed

Eyewash stations and first aid kits are present and serviced

Safety signs and floor markings are visible and in good condition

Document all findings and assign immediate corrective actions.

• Verify Forklift and Equipment Compliance

Forklifts and other material-handling equipment are a major focus during OSHA inspections. Ensure that:

All operators are properly trained and certified

Equipment has up-to-date inspection and maintenance logs

Load limits are clearly posted and followed

Warning alarms, seatbelts, and backup lights are functional

Keys are stored securely when equipment is not in use

Also, confirm that battery charging areas meet ventilation and signage requirements.

• Update Your Hazard Communication Program

Your warehouse likely contains adhesives, solvents, coatings, or treated wood—all of which fall under OSHA’s HazCom rules. Inspectors will check that you have:

A written Hazard Communication Plan

Updated Safety Data Sheets (SDS) for every chemical onsite

Proper labeling on all containers (including secondary ones)

Training documentation showing employees understand chemical risks

Keep SDSs accessible in both digital and physical formats for convenience and compliance.

• Review Emergency and Fire Safety Procedures

OSHA requires that all employees know what to do in an emergency. Prepare by verifying:

Fire extinguishers are mounted, inspected monthly, and easily accessible

Exit routes are clearly marked and unobstructed

Emergency evacuation plans are posted and understood

Fire drills are conducted and documented

Spill kits are available for chemical handling areas

Also, check that sprinkler heads are free of obstructions and not damaged.

• Ensure PPE Policies Are Enforced

Whether it’s steel-toed boots, high-visibility vests, or hearing protection, PPE must be worn correctly and consistently. OSHA inspectors will look for:

PPE that matches the hazards identified in your workplace assessment

Proper storage and cleanliness of reusable PPE

Records of PPE training and issue logs

Immediate access to required PPE at all relevant workstations

Spotty compliance in this area is a quick way to draw fines—and injuries.

• Train Supervisors and Front-Line Employees

Everyone should know what to do during an OSHA inspection. Prepare your team by:

Reviewing how to greet inspectors and answer basic questions

Ensuring supervisors understand OSHA rights and inspection protocols

Training employees to respond honestly and calmly if approached

Making sure documentation can be retrieved quickly on request

A prepared team sends a clear signal: safety isn’t just policy—it’s part of your culture.

• Keep All Safety Documentation Up to Date

OSHA inspectors often start with paperwork. Make sure you can quickly provide:

Injury and Illness logs (OSHA 300, 300A, 301)

Written safety programs (HazCom, PPE, forklift training, etc.)

Maintenance records and inspection logs

Records of safety meetings and employee training

Fire extinguisher and emergency equipment inspection tags

Keep these records organized, accessible, and updated regularly.

Final Thoughts

OSHA inspections don’t have to be stressful if you’re prepared. By staying proactive, running internal audits, and making safety a day-to-day priority, your warehouse can meet regulatory requirements—and more importantly, protect the people who keep your operation moving.

Safety and compliance aren’t just checklists. They’re competitive advantages in an industry where reliability matters.