An Analysis of Electrical Safety Trends and Top Issues
A study of citations, incidents, and fatalities related to industrial electrical safety in the US.
A new study by Grace Technologies examines the critical role of Lockout/Tagout (LOTO) procedures in preventing catastrophic electrical accidents. By analyzing LOTO violation trends from 2019 to 2023, the research sheds light on the industries and regions most at risk of electrical incidents.
Key Takeaways
- Despite a temporary decline in 2020, likely due to the COVID-19 pandemic, LOTO violations surged by 29% from 2022 to 2023, reaching levels similar to 2019.
- The manufacturing industry is disproportionately affected by LOTO violations, with Food Manufacturing (384 citations), Fabricated Metal Products (377), and Plastics & Rubber Products (202) leading in citation numbers and penalties.
- Las Vegas, with 88 reported injuries ranked third in reported work injuries, underscoring the importance of targeted safety interventions
Lockout/Tagout Violations Trend
OSHA's LOTO standard aims to prevent unexpected energization, startup, or release of stored energy, which could cause injuries. From 2019 to 2020, there was a notable decrease in violations, and in 2021, no violations were reported. However, from 2022 to 2023, there was a sharp 29% increase in violations, reaching almost the 2019 levels. From October 2022 through September 2023 the total number of citations across all industries is 2,532 from 1,368 inspections, resulting in $20,728,257 in penalties.
For Drew Allen, President and Chief Executive Officer of Grace Technologies: "The current escalation in LOTO violations signals a pivotal moment for industrial safety. This trend is a challenge and an opportunity to redefine industry standards. We are setting new benchmarks that exceed regulatory expectations by pioneering advanced safety training and deploying cutting-edge technologies. This approach addresses current gaps and paves the way for a future where workplace safety and operational excellence are inherently aligned."
Manufacturing industries are the most affected by LOTO violations, accounting for the majority of citations and penalties. The Food Manufacturing industry alone faced 384 citations across 181 inspections, resulting in penalties amounting to $7,495,528. Similarly, the Fabricated Metal Product Manufacturing sector received 377 citations, with penalties totaling $1,380,262. The Plastics and Rubber Products Manufacturing industry was cited 202 times, incurring penalties of $2,094,718.
Top 10 OSHA citations
LOTO consistently ranks among the top 10 OSHA citations. The trend for LOTO violations is similar to other top citations, with a dip in 2020-2021 and a rebound in 2022-2023. Fall Protection General Requirements consistently topped the list, peaking at 7,271 citations in 2023, up from 6,010 in 2019. Hazard Communication violations also remained high, with 3,213 citations in 2023. Ladders and Scaffolding violations saw increases, with Ladders reaching 2,978 citations in 2023 and Scaffolding with 2,859.
Which Cities Are Reporting the Most Injuries
The Bureau of Labor Statistics keeps track of every reported work injury. At the city level, Las Vegas ranks third among the top cities for reported injuries, indicating a significant number (88) of workplace injuries. On top of the list, Stafford, TX, reported 143 injuries, followed by Sacramento (92).
Most Frequent Accident
We analyzed over 300 electricity-related accident reports from 2021 to 2024. We did a text analysis to understand what were the most frequent causes of accidents. The most frequently mentioned causes of electrical accidents include contact with energized parts, leading to electrocution, and falls from heights such as ladders or scaffolding. Lack of proper lockout/tagout procedures and insufficient supervision and training also contribute significantly to these incidents. The high frequency of "Shock" (mentioned 445 times) and "Contact" (315) keywords in accident descriptions emphasizes the importance of proper LOTO procedures, as these terms are often associated with electrical hazards and unexpected equipment activation.
"This data analysis reveals a compelling trend in LOTO violations, suggesting not just a shortfall in current safety practices but a clear directive for the future. Proactive measures are becoming essential, not optional, in averting severe safety breaches. Integrating predictive analytics into our safety protocols is imperative as we advance to protect workers more effectively and anticipate potential risks before they manifest," said Drew Allen, President of Grace Technologies.
This study highlights the persistent importance of Lockout/Tagout procedures in workplace safety. Manufacturing industries are particularly at risk, and LOTO violations consistently rank among the top OSHA citations. The data also suggests that cities like Las Vegas may need to focus on improving workplace safety measures.
Methodology
This study analyzed OSHA, BLS, and accident report data to examine LOTO violation trends, industry impact, and city-level injury rates. Quantitative analysis identified trends and patterns, while qualitative analysis of accident reports revealed common causes of electrical accidents. The study highlights the critical role of LOTO compliance in preventing electrical injuries.
