Caution Signages: OSHA Rules, Workplace Uses & Buying Guide

Caution signage is the yellow-and-black alert reserved for hazards that could cause minor to moderate injury if ignored—think wet floors, low beams, and moving forklifts. Under OSHA 29 CFR 1910.145, the word “CAUTION” may appear only when the risk sits below “Danger” and “Warning” but still demands action. Using anything less, or nothing at all, can trigger fines just as quickly as a missing lockout tag.

This guide shows you exactly how to stay on the right side of the rule book. You’ll see the OSHA text translated into plain English, real-world examples of where caution signs belong, and a step-by-step buying checklist that removes the guesswork from procurement. Along the way, we’ll explain how proper placement and durable materials slash incident rates, protect budgets, and keep inspectors satisfied—setting you up to choose, install, and maintain compliant signs with confidence. Ready to tighten up your safety program? Let’s get started.

What OSHA Means by “Caution” Signage

OSHA groups accident-prevention signs into a clear pecking order: Danger ➝ Warning ➝ Caution ➝ Notice. “Caution” sits in the yellow middle ground—serious enough to require immediate attention, yet not life-threatening. Section 29 CFR 1910.145(c)(2) states, in plain language, that a caution sign must warn people about potential hazards or unsafe practices that could cause minor or moderate injury and must use the signal word “CAUTION” on a yellow background with black lettering.

That wording matters because mislabeling hazards is a citation magnet. If a condition can maim or kill, downgrading it to a yellow sign is a compliance failure just as sure as leaving it unmarked. Conversely, slapping a red “DANGER” label on every inconvenience waters down the impact of genuinely lethal risks and exposes the company to “willful” violation penalties. Current OSHA fine levels top $16,000 per violation for serious infractions and can exceed six figures for repeated or willful offenses—not to mention the workers’ comp and downtime that follow an injury.

Proper use of caution signages also supports OSHA’s General Duty Clause: employers must provide a workplace free from recognized hazards. When inspectors see the correct yellow placard placed at slip zones, low-clearance beams, or rotating couplings, they know your safety program recognizes the risk and has chosen the right level of control.

OSHA Severity Levels at a Glance

Category	Signal Word	Colors (ANSI Z535.1)	Typical Risk Example
Danger	DANGER	Red background, white text (or white panel, red text)	High-voltage switchgear, confined space with toxic atmosphere
Warning	WARNING	Orange background, black text	Hot surface on boiler, energized machinery during maintenance
Caution	CAUTION	Yellow background, black text	Wet floor, forklift traffic aisle, pinch point on conveyor
Notice	NOTICE	Blue header, white text	“Hearing protection required” policy sign, departmental information

The table makes one thing obvious: color and signal word are not interchangeable decorations—they declare the severity of the hazard at a glance.

Common Misconceptions to Avoid

• Using yellow caution tape as a substitute for a mounted sign—tape is temporary barricading, not regulated signage.
• Printing caution signs with creative colors or fonts; OSHA only recognizes the yellow/black scheme in legible sans-serif type.
• Treating “employee information” posters as safety signs; HR notices don’t satisfy 1910.145 requirements.
• Assuming pictograms are optional on every sign; if text alone cannot overcome language barriers, a standardized symbol is required.
• Placing caution signages too low or behind obstacles; ANSI calls for mounting in the normal line of sight, typically 4–6 ft above the walking surface.

Avoid these pitfalls and your caution signs will do exactly what OSHA intended—alert, prevent, and protect without triggering fines.

ANSI & OSHA Design Standards: Colors, Text & Symbols

OSHA tells you when to post a sign; ANSI tells you how that sign has to look so people instantly recognize the danger level. OSHA’s standard 1910.145 explicitly “recognizes the specifications set forth in ANSI Z535,” so following those voluntary consensus rules is the simplest proof of compliance. For caution signages, the governing parts are Z535.1 (colors) and Z535.2 (environmental & facility safety signs). Together they spell out every design detail—right down to the yellow shade that should hit a worker’s retina.

At minimum, a compliant caution sign must include five elements:

• Signal word: the word “CAUTION” in upper-case.
• Safety alert symbol: the exclamation mark inside an equilateral triangle, preceding the signal word.
• Hazard statement: a brief description of what could happen (e.g., “SLIP HAZARD”).
• Avoidance instructions: how to stay safe (“KEEP AISLE DRY”).
• Consequence statement: optional but recommended (“INJURY MAY OCCUR”).

Color fidelity matters. ANSI Z535.1 specifies “Safety Yellow” for the background behind the signal word panel and any surrounding field. Most printers match it to Pantone 109C (approx. hex #FFD100). Text and borders must be black (#000000) with at least 70 % contrast ratio. Veering away from these codes risks a citation for non-standard signage and, more importantly, dulls the instant recognition employees rely on.

Layout & Typography Requirements

Readability is king, so ANSI provides a simple viewing-distance rule of thumb:

Viewing Distance	Minimum Letter Height
7 ft (2 m)	1 in (25 mm)
14 ft (4 m)	2 in (50 mm)
21 ft (6 m)	3 in (76 mm)

Calculate quickly with: letter height (in) = distance (ft) ÷ 7. Stick with a sans-serif face such as Helvetica or Arial and capitalize only the first letter of each word in the message lines; the signal word itself stays ALL CAPS. The safety alert symbol must touch the left edge of the black signal panel and be the same height as the word “CAUTION.” Leave at least half a letter height of white (or yellow) space around the text block to keep things legible even in poor lighting.

Pictograms & ISO Compatibility

ANSI allows—yet doesn’t always require—a pictogram. Use one when:

1. Literacy or language barriers exist, or
2. A quick visual cue improves reaction time (moving forklifts, hot surfaces).

Choose artwork that meets ISO 7010 or ANSI Z535.3 so the symbol is universally recognized. Common options for caution signs include:

• Slip/fall (W001),
• Forklift traffic (W014),
• Hot surface (W017).

Avoid redrawing icons in clip-art style; inspectors may flag homemade graphics. Most reputable suppliers, including Safety Decals, maintain libraries of vector-based, standards-approved pictograms so your final sign passes both the eye test and the compliance audit.

Workplace Applications: Where and When to Use Caution Signs

The yellow panel should appear anywhere a worker could get banged up, bruised, or mildly burned if they aren’t paying attention. Typical hazard buckets include slip/trip areas, low overhead, pinch points, mild chemical irritants, moderate noise, and zones of frequent powered-industrial-truck traffic. Posting the correct caution signage keeps everyday risks from turning into recordable injuries and shows an OSHA inspector that you’ve distinguished “could hurt” from “could kill.”

Because no two facilities are identical, start with a walkthrough. Ask: Can the hazard be engineered out? If not, label it. Below are the environments where yellow signs earn their keep and the decision points for choosing portable versus permanent formats.

Industry-Specific Examples

• Manufacturing: Guarding gaps around rotating shafts, conveyor pinch points, robot cell access gates, and areas where coolant overspray makes the floor slick.
• Construction: Open trenches, rebar cages, overhead lifting zones, freshly poured concrete areas that limit traction.
• Warehousing & Logistics: Main forklift corridors, intersections with pedestrian aisles, dock levelers, battery-charging stations that release mild corrosives.
• Healthcare & Labs: Bio-waste tote routes, low-level radiation rooms, janitorial closets storing diluted cleaning chemicals.
• Education & Office: Wet-mopped hallways, copier rooms with hot fuser units, maintenance shops with compressed-air lines under 100 psi.

Temporary vs. Permanent Hazards

• Temporary (duration: hours to days)

  • Use folding floor signs, pop-up cones, or barricade tape.
  • Materials should be lightweight plastic or flexible vinyl for quick deployment.
  • Remove promptly to avoid “sign fatigue” once the hazard is gone.

• Permanent (duration: weeks to years)

  • Mount rigid plastic, aluminum, or laminated adhesive decals directly to walls, equipment guards, door panels, or guardrails.
  • Choose UV-stable inks and ORALITE® retro-reflective sheeting outdoors or in dim truck bays.
  • Review placement during annual safety audits; relocate if process flow changes.

Caution vs. Other Safety Sign Categories

Yellow caution signs address physical hazards that can cause minor or moderate harm. They differ from:

• Mandatory (blue): commands an action, e.g., “Wear Ear Protection.”
• Emergency/Safe Condition (green): points to exits or first-aid kits.
• Fire Equipment (red): identifies extinguishers and hose reels.

Mixing these categories—say, marking an eyewash station with a yellow sign—creates confusion and dilutes the color-coding system employees rely on. Keep the palette pure, and your entire safety communication program stays crisp, legal, and instantly understood.

Material, Size & Durability Choices

The best-designed caution sign fails if it peels off the wall after two weeks or is too small to read from a moving forklift. OSHA does not dictate material, but it does require that the message remain “readily visible and legible.” Your choice therefore hinges on three variables: environment, viewing distance, and expected service life. Below is a quick cheat-sheet you can use during a hazard assessment:

Substrate	Indoor	Outdoor	Water/Chem	Temp Range	Typical Life*	Good For
Adhesive vinyl (3–4 mil)	✔	Limited (UV fades)	Mild	‑20 °F to 140 °F	2–3 yr	Smooth machine panels, doors
Rigid plastic (0.060″)	✔	✔ (shade)	Moderate	‑20 °F to 160 °F	3–5 yr	Warehouse columns, cages
Enamel-coated aluminum (.040″)	✔	✔✔	Wash-down	‑40 °F to 250 °F	7–10 yr	Fences, exterior walls
Photoluminescent PVC	✔	Limited UV	Dry only	‑20 °F to 120 °F	5 yr	Egress routes during power loss
Magnetic vinyl	✔	✖	Dry only	‑20 °F to 140 °F	2 yr	Steel racks, dock plates

*Assumes normal wear; heavy abrasion or chemicals shorten life.

For harsh sites—salt-spray coasts, chemical processing, mine shafts—specify aluminum signs laminated with ORALITE® retro-reflective film. The micro-prismatic layer throws light back at drivers and withstands solvents, rain, and routine pressure-wash cycles. When caution labels must live inside an electrical panel or on rotating machinery, look for materials tested to UL 969 so adhesive strength and ink don’t fail under heat or vibration.

Sizing for Visibility

ANSI’s viewing-distance formula (letter height (in.) = distance (ft) ÷ 7) keeps text readable in a quick glance. The table below covers most floor and wall applications:

Max Viewing Distance	Minimum Letter Height	Suggested Sign Size*
10 ft	1.5 in	7 × 10 in
20 ft	3 in	10 × 14 in
30 ft	4.5 in	12 × 18 in
50 ft (forklift @ 6 mph)	7 in	18 × 24 in

*Common catalog dimensions; custom layouts may vary.

Factor in vehicle speed: a forklift traveling 6 mph covers roughly 9 ft per second, leaving only a couple seconds of recognition time. Upsizing letters or using reflective film buys operators those extra instants to react.

Specialty Finishes & Lifespan

A few add-ons can double or even triple service life:

• Lamination: Clear polyester over-laminate shields ink from scuffs, cleaners, and UV; essential on vinyl and plastics.
• Anti-graffiti coating: Fluoropolymer topcoat lets you wipe off paint and permanent marker—handy for public-facing gates.
• Retro-reflective (ORALITE® 5500, 5600): Micro-prisms return light to its source, making signs pop under headlights in dim docks.
• High-tack or foam adhesive: Bridges textured concrete or powder-coat finishes.
• Heat-resistant polyester: Survives engine housings up to 300 °F without curling.

Plan on inspecting caution signages annually. Replace when contrast drops 30 % (fading) or when edges curl more than ⅛ in—small defects that quickly snowball into unreadable warnings. Spending a few dollars on a higher-grade substrate today beats an OSHA citation—and a trip to the ER—tomorrow.

How to Select & Purchase OSHA-Compliant Caution Signages

Buying caution signages isn’t just a catalog exercise; it’s a mini risk-management project. Work through the steps below and you’ll end up with yellow signs that actually solve problems—­not collect dust in the storeroom.

1. Identify the hazard during a walkthrough or JHA.
2. Confirm severity fits the “minor or moderate injury” bracket (29 CFR 1910.145).
3. Measure viewing distance and note mounting surface and environment.
4. Draft the sign text/pictogram, matching ANSI Z535 rules.
5. Choose substrate, size, and finish for the site conditions.
6. Compare vendors, place order, and keep spec sheets on file for audits.

Compliance Checklist Before Buying

Print this list and hand it to anyone with purchasing authority:

• ❏ Has the hazard’s severity been verified as CAUTION, not Danger or Warning?
• ❏ Signal word “CAUTION,” safety-alert symbol, hazard, avoidance action, and consequence all included?
• ❏ Yellow background ≈ Pantone 109C; black text ≥ 70 % contrast?
• ❏ Minimum letter height meets distance ÷ 7 rule?
• ❏ Material rated for temperature, UV, chemicals, or wash-down where installed?
• ❏ Mounting method selected (adhesive, screws, magnetic, stanchion)?
• ❏ Documentation filed—purchase order, vendor specs, and inspection line item?

Comparing Top Suppliers

Not all sign makers are created equal. Weigh these factors before you click “Add to Cart”:

Criterion	General Catalog Site	Local Print Shop	Safety Decals (custom)
Stock sizes & quick ship	Excellent	Good	Good
Material options	Limited	Varies	Broad (ORAFOL, UL 969)
Custom ANSI layout	Extra fee	Possible	Included
Regulatory expertise	FAQ only	Low	High—consultation available
Lead time for custom	5–7 days	3–5 days	2–4 days
Made in USA	Sometimes	Yes	Yes

Safety Decals’ ability to tweak size, wording, or pictograms—and back it with Michigan-based compliance support—makes them a solid choice when “close enough” won’t cut it.

Cost vs. Savings: Budgeting Tips

• Economy adhesive vinyl: $5–$9 each
• Mid-grade rigid plastic: $12–$18
• Heavy-duty aluminum with ORALITE®: $30–$45

A single serious OSHA citation starts at $16,131 (2025 rate). Add $42,000 average direct cost for a recordable injury, and the ROI on a $20 sign becomes obvious. Order in volume—many suppliers apply 10–25 % discounts at 25, 50, or 100 pieces. For recurring consumables such as floor-stand signs, set up a replenishment program; predictable spend beats emergency overnight shipping every time.

Follow the workflow, run the checklist, and shop smart—your facility stays safe, compliant, and on budget.

Installation, Placement & Maintenance Best Practices

Putting money into OSHA-compliant caution signages pays off only if people can actually see them. ANSI Z535.2 calls for mounting signs “in a location easily noticed and legible under normal operating conditions.” In plain talk, that means eye-level, square to the line of travel, and free of visual clutter. Keep the center of the sign between 54 in and 66 in from the finished floor; that bracket covers the average worker’s sight line whether they’re walking or operating a seated forklift.

Popular mounting methods and when to use them:

• High-tack adhesive: Clean, smooth surfaces such as painted steel doors or machine guards. Degrease first so the bond lasts.
• Mechanical fasteners: #10 screws, rivets, or band clamps secure rigid plastic or aluminum to cinder block walls, posts, and fencing.
• Magnetic backers: Temporary cautions on steel racks or dock plates; peel off before they become permanent “wallpaper.”
• Floor decals & stanchions: Short-term wet-floor or traffic reroutes; choose textured, slip-resistant vinyl rated for pedestrian zones.

Weather is the silent killer of outdoor signs. If UV, salt spray, or routine wash-downs are in play, specify ORALITE® reflective aluminum or a laminate with UV inhibitors. Indoors, watch out for steam, caustic overspray, and forklift impacts; they age a sign faster than sunlight ever will.

Training Employees on Sign Meaning

Even a perfectly placed sign fails if workers don’t grasp its urgency. Cover these points in a 5-minute toolbox talk:

1. Color coding recap—red = danger, yellow = caution, blue = mandatory, green = safe condition.
2. Specific site examples: “This yellow panel by the press warns of a pinch point; keep hands clear.”
3. Reporting protocol: If a sign is missing, obscured, or damaged, notify maintenance before resuming work.

Reinforce with annual refresher quizzes and add sign recognition to new-hire orientation.

Inspection & Replacement Schedule

A quick monthly walk-through prevents “sign blindness.” Use this checklist:

• Is the message fully legible from normal approach distance?
• Are edges intact—no peeling, warping, or cracked mounting hardware?
• Is the sign unobstructed by stacked material or seasonal décor?
• Has the hazard changed, been engineered out, or escalated to a higher severity?

Document findings; replace or relocate any sign that fails. As a rule of thumb, indoor vinyl lasts 2–3 years, rigid plastic 3–5 years, and laminated aluminum 7–10 years—shorter if exposed to chemicals or direct impact. Budget now, avoid citations later.

Quick FAQs on Caution Signages

What are the 7 safety symbols?

• Explosive – risk of sudden blast.
• Flammable – ignites easily.
• Oxidizing – fuels combustion.
• Corrosive – eats metal or skin.
• Toxic – can be fatal if inhaled, swallowed, or absorbed.
• Harmful to environment – endangers wildlife or water.
• Health hazard – chronic issues like carcinogenicity.

What is a caution signage?
OSHA 29 CFR 1910.145 defines it as a yellow-and-black sign bearing the word “CAUTION” that warns of hazards capable of causing minor or moderate injury if not avoided.

What are the 5 main safety signs?

1. Prohibition (red): actions you must not do.
2. Warning (yellow): potential hazards, minor to severe.
3. Mandatory (blue): required behavior, e.g., PPE.
4. Safe condition (green): exits, first-aid, emergency equipment.
5. Fire safety (red equipment labels): extinguishers, hose reels.

Still stumped? Run questions past your safety manager or a knowledgeable supplier before you hit “print.”

Key Takeaways for a Safer Workplace

• “Caution” is the yellow middle ground in OSHA’s hierarchy—use it only for hazards that could cause minor or moderate injury.
• Follow ANSI Z535 for colors, wording, symbols, and letter height to prove compliance instantly.
• Match material and size to the environment and viewing distance; durability is part of legibility.
• Mount signs in the normal line of sight (4–6 ft high), train employees on meaning, and inspect at least annually.
• A $20 compliant sign today is cheaper than a $16 k citation tomorrow.

Need help? Check out custom OSHA-compliant caution signs and free compliance guidance from Safety Decals.