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.
