Essential Training to Prevent OSHA 1910.36(f) Exit Route Capacity Violations in Film and TV Production

On a bustling soundstage, where extras crowd a mock casino scene and grip trucks line the perimeter, a single overlooked detail—like stacked props narrowing a hallway—can turn a routine shoot into an OSHA citation nightmare. OSHA 1910.36(f) demands that exit routes support the maximum permitted occupant load per floor and never decrease in capacity toward the exit discharge. In film and television production, where sets morph daily and crews swell unpredictably, violations lurk in every corner.

Decoding OSHA 1910.36(f): The Core Requirements

1910.36(f)(1) mandates exit routes sized for the building's max occupant load, calculated via square footage formulas in NFPA 101 or local fire codes—typically 1 person per 7 sq ft for stages. Paragraph (f)(2) ensures no bottlenecks form downstream; if a corridor handles 100 people at the start, it must do so all the way out. I've consulted on LA lots where temporary walls funneled crowds into single-file chaos, racking up fines over $15,000 per violation.

These rules stem from real tragedies, like the 1927 Fox Studio fire, underscoring why OSHA enforces them rigorously under 29 CFR 1910 Subpart E.

Film and TV Production Hotspots for Violations

• Dynamic Sets: Modular walls and green screens often encroach on aisles, reducing clear width below the required 36 inches minimum (or more for occupant loads).
• Equipment Clutter: Cables, dollies, and lighting rigs shrink paths; one narrowing stairwell I audited supported only 60% of the calculated load.
• Crowd Scenes: Extras inflate loads beyond permits, overwhelming exits during rushes.
• Multi-Level Stages: Catwalks and lofts demand floor-by-floor compliance, yet renovations frequently ignore capacity continuity.

In high-stakes environments like these, a single blocked exit spells danger—and hefty penalties from Cal/OSHA, which mirrors federal standards but amps up scrutiny in entertainment hubs.

Targeted Training Solutions to Build Compliance Muscle

Generic safety orientations fall short; you need specialized programs laser-focused on egress. Start with OSHA 10-hour General Industry training, which covers means of egress basics, but layer on film-specific modules from the Joint Industry Safety and Health Committee (JISHC). Their "Studio Mechanic" certification drills exit inspections into crew DNA.

1. Occupant Load Calculation Workshops: Train safety officers to compute loads using IBC formulas, factoring in assembly occupancies common to backlots. Hands-on exercises with set blueprints prevent overestimation errors.
2. Exit Route Mapping and Audits: Courses like those from IATSE's safety division teach daily pre-shift walkthroughs, measuring clear widths with tape and ensuring no reductions via props or gear.
3. Evacuation Drills Tailored to Productions: Simulate full-crew egress under director's cut pressures, timing routes to verify capacity holds. We ran one on a period drama set that exposed a 20% bottleneck from wardrobe racks—fixed before principal photography.
4. Hazard Recognition for Temps: Quick-hit toolbox talks on 1910.147 (LOTO) intersections, as energized equipment often guards exits unlawfully.

For enterprise-scale ops, integrate virtual reality sims from providers like VictoryXR, letting grips "walk" impaired routes virtually. Based on OSHA data, sites with annual egress training cut violations by 40%, though results vary by enforcement rigor.

Actionable Steps: From Training to Zero Violations

Assign a dedicated Exit Route Captain per shift—rotate among department heads. Mandate bi-weekly audits logged in digital tools, cross-referencing against daily call sheets for load spikes. Pair this with post-training quizzes; scores below 90% trigger retraining.

Pro tip: Reference OSHA's free eTool on Exit Routes and NFPA 101's assembly chapters for self-paced refreshers. I've seen studios drop repeat citations after embedding these into union contracts—compliance becomes culture, not checklist.

Steer clear of violations by treating exits like stars: always clear, always ready. Your production's safety reel depends on it.