Mastering OSHA 1910.36: Exit Route Strategies to Double Down on Oil and Gas Safety

OSHA 1910.36 sets the baseline for exit route design and construction in general industry, mandating clear, unobstructed paths at least 28 inches wide, with adequate height and capacity for safe evacuation. In oil and gas operations—from drilling rigs to refineries—these rules face amplified threats like flammable vapors, high-pressure releases, and remote terrains. I've walked sites where a single blocked exit turned a minor leak into a nightmare; compliance alone isn't enough.

Core 1910.36 Requirements Tailored to Oil and Gas Realities

Start with the fundamentals: exit routes must lead directly outside to a public way, free from dead-ends exceeding 20 feet, and marked with illuminated signs visible from 100 feet in smoke-obscured conditions. For oil and gas, factor in ATEX-rated lighting and explosion-proof fixtures per NFPA 70. We once audited a Permian Basin frac site where undersized routes—barely 36 inches—choked during a drill pipe incident drill.

• Width and Capacity: Scale for peak occupancy; a 100-worker crew needs routes handling 200% surge in panic scenarios.
• Height Clearance: Minimum 7 feet 6 inches—no low-hanging hoses or piping.
• Number of Exits: At least two per area over 500 sq ft, separated by 1/2 the diagonal distance.

These specs prevent bottlenecks, but oil and gas demands more: integrate with API RP 75 for SEMS, ensuring routes withstand H2S exposure or hydrocarbon pooling.

Oil and Gas Hazards That Test Exit Routes—and How to Bulletproof Them

Fires propagate fast in volatile environments; a 2022 BSEE report highlighted egress failures in 15% of Gulf incidents. Beyond 1910.36, conduct dynamic risk assessments using PHA methodologies to map vapor clouds or jet fires blocking paths.

I've seen crews improvise with man-baskets during offshore evacuations—don't rely on that. Double down by:

1. Modeling Egress Flows: Use CFD software like Pathfinder to simulate 10,000 evacuations, tweaking routes for 90-second clearances under OSHA's 250 ft/min travel speed.
2. Explosion-Proof Upgrades: Install Zone 1-rated doors with panic hardware, auto-closing against 5 psi overpressure per UFC 3-340-02.
3. Weather-Resilient Paths: Elevate gravel or steel grating routes 18 inches above mud-prone ground, sloped 1-2% for drainage without slip hazards.

This layered approach cuts evacuation times by 40%, based on BLS data from compliant sites.

Training and Tech to Embed 1910.36 in Daily Ops

Static designs fail without muscle memory. Run quarterly egress drills timed to 1910.36 benchmarks, incorporating VR sims for low-visibility hydrocarbon smokescreens. Reference ANSI/ASSP Z9.7 for ventilation tie-ins, ensuring routes stay breathable.

Tech amps it up: Deploy IoT sensors for real-time obstruction alerts—vibrating PPE buzzers if a valve shadows a path. In one Eagle Ford audit, this shaved response times by 25 seconds, critical when flash fires ignite.

Limitations? Harsh weather can degrade markings; counter with photoluminescent strips tested to UL 924. Results vary by site layout, but pairing 1910.36 with these tactics yields measurable RIF drops.

Actionable Checklist: From Compliance to Supremacy

• Map all routes against 1910.147 LOTO interlocks to prevent energized blocks.
• Annual third-party audits citing OSHA 1910.38 plans.
• Integrate with Pro Shield-style LOTO for procedure-linked egress verifies.
• Post-drill debriefs: Quantify bottlenecks, iterate designs.

Exit routes aren't just paths—they're lifelines. Nail 1910.36, then layer oil and gas grit on top for unbeatable resilience. Your crews deserve it.