OSHA 511 GENERAL INDUSTRY 2025
COMPLETE SAFETY REVIEW & STUDY PREP
MANUAL || UPDATED VERSION
Module 1: Introduction to OSHA
1. Q: What is the primary mission of the Occupational Safety and Health Administration
(OSHA)?
A: To assure safe and healthful working conditions for working men and women by
setting and enforcing standards and by providing training, outreach, education, and
assistance.
A: To increase workplace productivity and profitability.
2. Q: The OSH Act of 1970 provides workers with the "Right to Know" about hazards in
their workplace. What two other fundamental rights does it provide?
A: The right to file a confidential complaint with OSHA and the right to be free from
retaliation for exercising safety rights (Whistleblower Protection).
A: The right to paid leave and the right to a union representative.
3. Q: Who is covered under the OSH Act?
A: Most private sector employers and employees in the 50 states and certain U.S.
jurisdictions.
A: Only federal government employees and construction companies.
4. Q: What is a key difference between an OSHA standard and an OSHA regulation?
A: "Standards" are specific rules for hazards (e.g., fall protection). "Regulations" are the
broader procedural and legal frameworks for how OSHA operates and enforces the law.
A: They are interchangeable terms with no difference.
5. Q: What is the General Duty Clause, Section 5(a)(1) of the OSH Act?
A: It requires employers to furnish a workplace free from recognized hazards that are
causing or are likely to cause death or serious physical harm.
A: It requires employees to follow all safety rules without question.
Module 2: Walking-Working Surfaces
6. Q: At what height does OSHA require guardrails on a general industry walking-working
surface?
,A: 4 feet (42 inches, plus or minus 3 inches).
A: 6 feet.
7. Q: Fixed stairs must be installed for ascent to a vertical height exceeding how many feet?
A: 4 feet.
A: 10 feet.
8. Q: What is the maximum permitted vertical rise for a single ladder section before a
landing platform is required?
A: 30 feet.
A: 24 feet.
9. Q: A portable ladder used for access to an upper surface must extend at least how many
feet above the landing?
A: 3 feet.
A: 2 feet.
10. Q: What is the required minimum design load for a ladder?
A: At least 4 times the maximum intended load.
A: 2 times the weight of the user.
Module 3: Exit Routes, Emergency Action Plans, Fire Prevention
11. Q: What are the three parts of an "Exit Route" as defined by OSHA?
A: Exit access, exit, and exit discharge.
A: Alarm, evacuation map, and muster point.
12. Q: What is the minimum number of exit routes required for a workplace with 60
employees?
A: At least two, unless the travel distance and occupant load allow for one under specific
criteria.
A: One.
13. Q: Doors that swing into an exit route must not reduce the clear width to less than how
many inches?
A: Not less than 32 inches when fully open.
A: Not less than 28 inches.
14. Q: What must an employer have if they have a fixed extinguishing system?
A: A fixed extinguishing system must have a distinctive alarm or signal.
A: A dedicated fire watch 24/7.
, 15. Q: What class of fire involves flammable liquids, greases, and gases?
A: Class B.
A: Class A.
Module 4: Electrical Safety (General Industry)
16. Q: What are the three essential components of an Electrical Safety Program?
A: Training, safety-related work practices, and a lockout/tagout program.
A: Voltage meters, rubber gloves, and circuit breakers.
17. Q: What does GFCI stand for and what does it do?
A: Ground-Fault Circuit Interrupter; it quickly breaks the circuit to prevent severe electric
shock by detecting a difference in current between hot and neutral wires.
A: Ground-Fuse Circuit Inhibitor; it prevents power surges.
18. Q: Flexible cords (extension cords) may NOT be used as a substitute for what?
A: Fixed wiring (permanent installation).
A: Power strips.
19. Q: What is the minimum working space clearance in front of an electrical panel rated at
480V?
A: 3 feet (36 inches) of clear, unobstructed space.
A: 2 feet.
20. Q: According to OSHA, what is the primary purpose of Lockout/Tagout (LOTO)?
A: To safeguard employees from the unexpected energization or startup of machines
and equipment, or the release of hazardous energy during servicing or maintenance.
A: To identify who is working on a piece of equipment.
Module 5: Personal Protective Equipment (PPE)
21. Q: What is the first step in the PPE hazard assessment process?
A: Survey the workplace for hazards.
A: Issue the most common PPE to all employees.
22. Q: When must employers provide PPE to employees at no cost?
A: When it is required to comply with an OSHA standard.
A: Only for full-time employees.
23. Q: What is the primary purpose of a risk assessment for respirator selection?
A: To identify and quantify the contaminant (type, concentration) and oxygen level.
, A: To find the least expensive respirator option.
24. Q: What must be included in a written respiratory protection program?
A: Medical evaluations, fit testing, procedures for use, cleaning, storage, and training.
A: Just a list of employees who need respirators.
25. Q: What type of hearing protection is required when noise exposure exceeds the OSHA
Action Level of 85 dBA as an 8-hour TWA?
A: Hearing protection must be made available. It is required when exposures exceed the
PEL of 90 dBA. (Hearing Conservation Program required at 85 dBA).
A: Ear plugs are required at all times over 85 dBA.
Module 6: Hazard Communication (GHS)
26. Q: What is the purpose of the Hazard Communication Standard (HCS)?
A: To ensure information about chemical hazards and associated protective measures is
communicated to workers.
A: To ban the use of dangerous chemicals.
27. Q: What are the four major elements of GHS adopted into the HCS?
A: Hazard classification, standardized labels (pictograms, signal words), Safety Data
Sheets (SDS), and employee training.
A: Chemical storage, disposal, purchase records, and labeling.
28. Q: How many sections must a compliant Safety Data Sheet (SDS) have?
A: 16 sections.
A: 9 sections.
29. Q: What does a skull and crossbones pictogram represent?
A: Acute toxicity (fatal or toxic).
A: Any health hazard.
30. Q: Who is responsible for labeling secondary containers in the workplace?
A: The employer.
A: The chemical manufacturer.
Module 7: Hazardous Materials (Flammable/Combustible)
31. Q: What is the flash point of a Class IB flammable liquid?
A: Below 73°F and with a boiling point at or below 100°F.
A: Between 100°F and 140°F.
COMPLETE SAFETY REVIEW & STUDY PREP
MANUAL || UPDATED VERSION
Module 1: Introduction to OSHA
1. Q: What is the primary mission of the Occupational Safety and Health Administration
(OSHA)?
A: To assure safe and healthful working conditions for working men and women by
setting and enforcing standards and by providing training, outreach, education, and
assistance.
A: To increase workplace productivity and profitability.
2. Q: The OSH Act of 1970 provides workers with the "Right to Know" about hazards in
their workplace. What two other fundamental rights does it provide?
A: The right to file a confidential complaint with OSHA and the right to be free from
retaliation for exercising safety rights (Whistleblower Protection).
A: The right to paid leave and the right to a union representative.
3. Q: Who is covered under the OSH Act?
A: Most private sector employers and employees in the 50 states and certain U.S.
jurisdictions.
A: Only federal government employees and construction companies.
4. Q: What is a key difference between an OSHA standard and an OSHA regulation?
A: "Standards" are specific rules for hazards (e.g., fall protection). "Regulations" are the
broader procedural and legal frameworks for how OSHA operates and enforces the law.
A: They are interchangeable terms with no difference.
5. Q: What is the General Duty Clause, Section 5(a)(1) of the OSH Act?
A: It requires employers to furnish a workplace free from recognized hazards that are
causing or are likely to cause death or serious physical harm.
A: It requires employees to follow all safety rules without question.
Module 2: Walking-Working Surfaces
6. Q: At what height does OSHA require guardrails on a general industry walking-working
surface?
,A: 4 feet (42 inches, plus or minus 3 inches).
A: 6 feet.
7. Q: Fixed stairs must be installed for ascent to a vertical height exceeding how many feet?
A: 4 feet.
A: 10 feet.
8. Q: What is the maximum permitted vertical rise for a single ladder section before a
landing platform is required?
A: 30 feet.
A: 24 feet.
9. Q: A portable ladder used for access to an upper surface must extend at least how many
feet above the landing?
A: 3 feet.
A: 2 feet.
10. Q: What is the required minimum design load for a ladder?
A: At least 4 times the maximum intended load.
A: 2 times the weight of the user.
Module 3: Exit Routes, Emergency Action Plans, Fire Prevention
11. Q: What are the three parts of an "Exit Route" as defined by OSHA?
A: Exit access, exit, and exit discharge.
A: Alarm, evacuation map, and muster point.
12. Q: What is the minimum number of exit routes required for a workplace with 60
employees?
A: At least two, unless the travel distance and occupant load allow for one under specific
criteria.
A: One.
13. Q: Doors that swing into an exit route must not reduce the clear width to less than how
many inches?
A: Not less than 32 inches when fully open.
A: Not less than 28 inches.
14. Q: What must an employer have if they have a fixed extinguishing system?
A: A fixed extinguishing system must have a distinctive alarm or signal.
A: A dedicated fire watch 24/7.
, 15. Q: What class of fire involves flammable liquids, greases, and gases?
A: Class B.
A: Class A.
Module 4: Electrical Safety (General Industry)
16. Q: What are the three essential components of an Electrical Safety Program?
A: Training, safety-related work practices, and a lockout/tagout program.
A: Voltage meters, rubber gloves, and circuit breakers.
17. Q: What does GFCI stand for and what does it do?
A: Ground-Fault Circuit Interrupter; it quickly breaks the circuit to prevent severe electric
shock by detecting a difference in current between hot and neutral wires.
A: Ground-Fuse Circuit Inhibitor; it prevents power surges.
18. Q: Flexible cords (extension cords) may NOT be used as a substitute for what?
A: Fixed wiring (permanent installation).
A: Power strips.
19. Q: What is the minimum working space clearance in front of an electrical panel rated at
480V?
A: 3 feet (36 inches) of clear, unobstructed space.
A: 2 feet.
20. Q: According to OSHA, what is the primary purpose of Lockout/Tagout (LOTO)?
A: To safeguard employees from the unexpected energization or startup of machines
and equipment, or the release of hazardous energy during servicing or maintenance.
A: To identify who is working on a piece of equipment.
Module 5: Personal Protective Equipment (PPE)
21. Q: What is the first step in the PPE hazard assessment process?
A: Survey the workplace for hazards.
A: Issue the most common PPE to all employees.
22. Q: When must employers provide PPE to employees at no cost?
A: When it is required to comply with an OSHA standard.
A: Only for full-time employees.
23. Q: What is the primary purpose of a risk assessment for respirator selection?
A: To identify and quantify the contaminant (type, concentration) and oxygen level.
, A: To find the least expensive respirator option.
24. Q: What must be included in a written respiratory protection program?
A: Medical evaluations, fit testing, procedures for use, cleaning, storage, and training.
A: Just a list of employees who need respirators.
25. Q: What type of hearing protection is required when noise exposure exceeds the OSHA
Action Level of 85 dBA as an 8-hour TWA?
A: Hearing protection must be made available. It is required when exposures exceed the
PEL of 90 dBA. (Hearing Conservation Program required at 85 dBA).
A: Ear plugs are required at all times over 85 dBA.
Module 6: Hazard Communication (GHS)
26. Q: What is the purpose of the Hazard Communication Standard (HCS)?
A: To ensure information about chemical hazards and associated protective measures is
communicated to workers.
A: To ban the use of dangerous chemicals.
27. Q: What are the four major elements of GHS adopted into the HCS?
A: Hazard classification, standardized labels (pictograms, signal words), Safety Data
Sheets (SDS), and employee training.
A: Chemical storage, disposal, purchase records, and labeling.
28. Q: How many sections must a compliant Safety Data Sheet (SDS) have?
A: 16 sections.
A: 9 sections.
29. Q: What does a skull and crossbones pictogram represent?
A: Acute toxicity (fatal or toxic).
A: Any health hazard.
30. Q: Who is responsible for labeling secondary containers in the workplace?
A: The employer.
A: The chemical manufacturer.
Module 7: Hazardous Materials (Flammable/Combustible)
31. Q: What is the flash point of a Class IB flammable liquid?
A: Below 73°F and with a boiling point at or below 100°F.
A: Between 100°F and 140°F.
