Cannabis Worker Safety in 2025: NIOSH Guidance Updates and What Cultivation, Extraction, and Beverage Facilities Must Change

The Evolving Landscape of Cannabis Worker Safety in 2025

The fast-paced expansion of the cannabis industry brings not only economic opportunity but also a host of worker safety challenges. The National Institute for Occupational Safety and Health (NIOSH) significantly expanded its cannabis worker safety materials in 2024 and 2025, responding to both federal and state demand for better protections in cultivation, extraction, beverage, and processing environments. Operators face increased scrutiny as OSHA and several state agencies have rolled out cannabis-specific emphasis programs, and national fire and safety standards continue to evolve.

This post distills the latest NIOSH guidance, focusing on how to translate complex regulatory requirements into audit-ready Standard Operating Procedures (SOPs). We’ll highlight the hazards, new rules from the International Fire Code (IFC) and NFPA 660, and provide a comprehensive readiness checklist for operators heading into 2026.

Key Hazards and Exposures in Cannabis Operations

Sensitizers & Allergens

NIOSH research continues to highlight that plant dust, ground cannabis material, and pollen are potent respiratory sensitizers, increasing risk for asthma and work-related allergies. Processing, trimming, and drying operations frequently present high-exposure scenarios (CDC: NIOSH Cannabis Hazards).

Solvent & Chemical Exposures

Extraction and formulation labs often use flammable solvents, concentrated acids, or bases. NIOSH has specifically flagged risks of hydrocarbon, ethanol, and CO2 extraction. Operators must manage:

• Airborne solvent concentrations
• Exposure to residual chemicals
• Process-related fires/explosions

Dust, Particulates & Combustible Dust

Cannabis dust is now regulated as a hazardous chemical by OSHA’s Hazard Communication Standard (29 CFR 1910.1200), requiring hazard evaluation and SDSs (Mass Cannabis Control Commission Bulletin, Nov 2024). Accumulations can also present a combustible dust hazard, newly governed by NFPA 660 (2025).

Carbon Dioxide (CO2) Enrichment

CO2 supplementation is common for indoor cultivation. Exposures above 2,000 ppm are possible in improperly ventilated rooms. The NIOSH recommended exposure limit (REL) is 5,000 ppm for an 8-hour TWA (NIOSH CO2 Guidance).

Ergonomic Hazards & Heat Illness

Long trimming sessions, repetitive motions, and awkward postures contribute to musculoskeletal disorders. In states with hot climates, heat stress has resulted in hospitalizations and fatalities for cultivation staff, making prevention a compliance priority.

Federal and State Enforcement: 2025 Focus Areas

Federal OSHA and State Emphasis Programs

OSHA rolled out new cannabis-specific Local Emphasis Programs (LEPs) and State Plans are following suit (OSHA Directive CPL 24-04 EP). These programs now target:

• Cultivation (outdoor, indoor, greenhouse)
• Extraction and processing
• Edible and beverage manufacturing

Unannounced inspections focus on:

• Ventilation and air monitoring
• Hazard communication and chemical hygiene
• Personal Protective Equipment (PPE)
• Lockout/tagout (LOTO)
• Incident investigation and heat stress protocols

States like Colorado and Massachusetts have launched parallel initiatives, increasing the risk for citations and requiring internal audits (OSHA emphasis in CO).

New Extraction Rules: IFC and NFPA 660

The 2025 International Fire Code and the publication of NFPA 660 are shaping explosive and combustible dust risk management—especially for extraction, beverage, and processing spaces. Expect:

• Consolidated, stricter requirements for dust hazard analysis
• Housekeeping, grounding/bonding, and process ventilation
• Spark control measures
• Emergency response planning requirements (NFPA 660 Compliance Guide)

Translating NIOSH & Regulatory Guidance into Audit-Ready SOPs

Meeting and exceeding safety standards means building compliance directly into your operations. Here’s how to align with 2025 expectations:

1. Exposure Controls & Engineering

• Install and maintain local exhaust ventilation (LEV) for trimming, grinding, and solvent transfer stations.
• Use enclosed, negatively-pressured rooms for extraction.
• HEPA-filter dust collection systems to control airborne plant material.
• Design CO2 enrichment zones with real-time atmospheric monitors and interlocks.

2. Respiratory Protection Program

• Conduct hazard assessments for allergens, particulates, and solvents.
• Provide NIOSH-approved masks/respirators and enforce fit-testing.
• Maintain written respiratory SOPs compliant with OSHA’s 1910.134.

3. Lockout/Tagout (LOTO) & Chemical Hygiene

• Develop written LOTO procedures for all mechanical and electrical systems.
• Store and label solvents per GHS and OSHA HCS.
• Implement chemical spill response plans, maintain eyewash and shower stations.

4. CO2 Monitoring & Alarm Systems

• Set low and high threshold alarms no higher than 5,000 ppm.
• Test and calibrate sensors quarterly.
• Train staff on evacuation procedures for atmospheric releases.

5. Incident Reporting & Investigation

• Ensure all injuries, exposures, and near misses are reported within 24 hours.
• Use root-cause analysis for each incident.
• Maintain logs for OSHA recordkeeping and state reporting.

6. Sensitizer & Allergen Control

• Offer gloves, sleeves, and protective clothing.
• Require handwashing before/after handling raw plant material.
• Schedule routine surface and air monitoring for biological particulates.

7. Ergonomics and Heat Illness Prevention

• Rotate tasks to reduce repetitive motion disorders.
• Install mechanical trimming tables and anti-fatigue mats.
• Train in heat illness recognition; ensure shaded rest zones and cool potable water are always available.

2025-2026 Readiness Checklist: Budget & Plan Now

To help your facility prepare for audits and maintain continuous compliance, build these priorities into your 2025 safety and CAPEX budgets:

Ventilation & LEV Upgrades

• Assess and upgrade air handling for all high-dust and extraction zones.

CO2 Monitoring Expansion

• Install new sensors or expand coverage to all cultivation and beverage spaces.

Combustible Dust Compliance (NFPA 660)

• Conduct a dust hazard analysis by Q3 2025.
• Upgrade dust collectors by Q1 2026 to meet consolidated NFPA standards.

PPE and Respiratory Fit-Testing

• Schedule annual fit-testing and replenishment for all PPE stocks.

LOTO and Chemical Hygiene Reviews

• Audit and update written procedures to ensure process changes are reflected.

Heat Illness Protocol Review

• Update heat illness plans before summer 2025. Document shaded rest zones and monitor high temperatures.

Emergency and Incident Documentation

• Practice and drill incident response. Update documentation and training materials each quarter.

Conclusion: Your 2025 Safety Roadmap

Cannabis industry operators must treat worker safety as a dynamic, regulatory-driven process that evolves yearly. With new NIOSH guidance, OSHA and state-level emphasis programs, and the rollout of IFC and NFPA 660 rules, it’s essential for cultivation, extraction, and beverage businesses to move beyond basic compliance.

Failing to proactively translate guidance into detailed SOPs and audited procedures can result in costly enforcement actions and increased business risk—while robust programs support productivity, employee retention, and your public brand.

Stay ahead of the regulatory curve with the latest updates, audit templates, and best practices at CannabisRegulations.ai. Use our tools to develop, implement, and maintain worker protection plans that ensure top-tier cannabis compliance throughout 2025 and beyond.