OSHA 1910.36(b)(1) Compliance Checklist: Securing Two Exit Routes for Film and TV Production

In film and TV production, where sets transform hourly and crews swarm under hot lights, a blocked exit can turn a minor mishap into chaos. OSHA's 1910.36(b)(1) mandates at least two exit routes—positioned as far apart as practical—to ensure prompt evacuation if one path clogs with smoke or fire. We've audited countless soundstages and location shoots; ignoring this invites citations and worse.

Grasping 1910.36(b)(1) in Production Contexts

This standard applies to all workplaces, but film sets amplify risks: pyrotechnics, fog machines, towering grip rigs, and transient builds. Exit routes must accommodate peak occupancy, remain unobstructed, and diverge enough—ideally separated by half the diagonal dimension of the space or more, per OSHA interpretations. Exceptions under (b)(3) allow one exit for spaces with fewer than 50 occupants if travel distance to the exit is under 75 feet, but don't bank on it for crowded stages.

I've walked sets post-incident where a single propane heater blocked the secondary route, stranding 40 crew members. Compliance isn't optional; it's scripted into safe operations.

Why Two Exit Routes Matter on Set

Picture a night shoot: practical effects ignite, cables snake everywhere, talent and extras pack the space. One exit compromised? Evacuation grinds to a halt. OSHA data shows exit blockages contribute to 10% of workplace fire fatalities. In production, where IATSE and Teamsters demand rigor, nailing 1910.36(b)(1) builds trust, cuts insurance premiums, and keeps the director's vision rolling uninterrupted.

Your Step-by-Step 1910.36(b)(1) Compliance Checklist

Use this checklist before every major setup. Document each step with photos and sign-offs—OSHA loves paper trails.

1. Conduct a Space Assessment. Map your set or stage, noting total occupancy (crew + talent + extras). Measure the longest diagonal; exits should split it roughly in half. For a 100x50 ft soundstage, aim for 50+ ft separation.
   • Verify against (b)(3) exceptions: <50 occupants and <75 ft travel distance?
   • Flag temporary structures like tents or greenscreens that shrink effective space.
2. Inspect and Clear Primary/Secondary Routes. Walk both paths under full load—props, lighting stands, wardrobe racks. Nothing wider than 28 inches or taller than 7 ft overhead.
   • Remove hazards: coiled cables, sandbags, fogger tanks.
   • Test doors: swing freely, no locks except permitted panic hardware.
3. Install and Verify Signage. Illuminated 'EXIT' signs visible from 100 ft, arrows pointing to both routes. No funny business with set dressing obscuring them.
   • Check emergency lighting: batteries charged, paths lit to 1 ft-candle minimum.
   • In low-light shoots, add photoluminescent backups.
4. Account for Peak Occupancy and Flow. Calculate max users per route: width x 0.2 inches/person (e.g., 36-inch door = 180 persons).
   • Simulate evac: time a drill from farthest point (<250 ft travel distance max).
   • Adjust for mobility aids or costumes that slow movement.
5. Integrate with Production Schedules. Pre-mark no-build zones around exits in shot plans. Daily sweeps by key grip or safety officer.
   • For location shoots (warehouses, backlots), scout dual accesses upfront.
   • Hot sets with practical fire? Double-check post-reset.
6. Train and Document. Brief cast/crew on routes during safety meetings—use floor plans.
   • Log inspections in your JHA or incident software.
   • Reference OSHA's eTool for egress: osha.gov/etools.
7. Audit and Maintain. Monthly reviews, plus post-alteration checks. Common pitfalls: grip tape residue on floors, forgotten C-stands.
   • Test for blockages in scenarios like power loss or prop collapses.
   • Consult NFPA 101 for deeper fire egress alignment.

Pro Tips from the Field

On a recent LA studio gig, we rerouted a secondary exit behind the cyclorama—saved the day when a fresnel tipped. Balance is key: exits can't compromise shots, but hacks like flimsy partitions fail inspections. If variances apply (rare in production), petition OSHA formally.

Compliance with 1910.36(b)(1) isn't a scene steal—it's the safety net letting creativity thrive. Run this checklist religiously; your crew will thank you when the klaxon sounds.