Debunking Common Misconceptions About OSHA 1910.36(g): Exit Route Height and Width Requirements

OSHA's 1910.36(g) sets clear rules for exit route dimensions to ensure safe evacuation. Yet, in my two decades of EHS consulting across California manufacturing plants and warehouses, I've seen teams misinterpret these specs time and again. These errors can lead to citations, failed inspections, or worse—delayed evacuations. Let's cut through the confusion with straight facts from the standard.

The Height Myth: "Everything Needs 7'6\" Clear Headroom"

1910.36(g)(1) states: The ceiling must be at least 7 feet 6 inches high, but projections from the ceiling—like beams or fixtures—can dip to 6 feet 8 inches from the floor. A common misconception? Assuming the entire path demands uniform 7'6\" clearance. Nope.

I've walked facilities where managers hung low pipes at 7 feet, thinking they'd pass muster. OSHA inspectors flagged them instantly. The rule protects average adult heights during panic—stooped rushes don't count on rigid uniformity. Pro tip: Measure projections independently. If your sprinklers or ducts encroach below 6'8\", engineer fixes like rerouting or guards. Real-world fix? We retrofitted a Bay Area warehouse with angled beam covers for $5K, dodging a $14K fine.

Width Traps: "28 Inches Works for Every Exit Access"

1910.36(g)(2) mandates exit accesses at least 28 inches wide everywhere. Sounds simple—until you hit single-exit scenarios. Here's the kicker: If there's only one exit access to an exit or discharge, those must match or exceed that width.

• Misconception 1: All corridors auto-qualify at 28 inches, regardless of traffic.
• Misconception 2: Exits can narrow downstream.

Teams often overlook this in older buildings. During a Silicon Valley tech campus audit, we found a 26-inch doorway bottlenecking a 32-inch hall—clear violation. Calculate widths point-by-point; temporary obstructions don't fly either.

Occupant Load Overlook: "Width is Fixed, Not Load-Based"

1910.36(g)(3) requires exit route widths to handle the maximum permitted occupant load per floor. Forget the 28-inch baseline here—it's about capacity. Use NFPA 101 or local codes for load calcs (e.g., 100 sq ft per occupant in offices).

Picture a bustling distribution center: 200 workers, but exits sized for 100. Disaster waiting. I've consulted sites where "we've never had issues" was the defense—until OSHA's formula proved otherwise. Formula: Occupant load × 0.2 inches per person minimum (or wider per code). Always document your calcs; auditors love paper trails.

Projections Panic: "No Objects Allowed in Exit Routes"

1910.36(g)(4) is blunt: Projections can't shrink the route below minimum widths. Misconception? Zero-tolerance for anything overhanging.

Handrails, signs, or equipment guards are fine if they preserve clear width. In a recent LA fabrication shop consult, unprotected shelving ate 4 inches—we added rollers to swing them clear. Balance is key: OSHA prioritizes usable space over sterile emptiness. Reference Appendix E to 1910.36 for diagrams—they're gold.

Actionable Steps to Compliance

Don't guess—measure. Start with laser levels for heights, tape for widths, and spreadsheets for loads. Train your team annually; misconceptions die hard without refreshers. For depth, dive into OSHA's full 1910.36 page or NFPA 101. Individual facilities vary—soil tests, seismic retrofits in quake country like California add layers. Based on field data, compliant routes cut evacuation times 20-30%, per NIOSH studies.

Fix these now. Your people deserve exits that work when seconds count.