OSHA 1910.36(g): Exit Route Height and Width Essentials for Chemical Processing

In chemical processing plants, where spills can ignite in seconds and toxic vapors demand split-second evacuations, exit routes aren't just pathways—they're lifelines. OSHA 1910.36(g) sets ironclad minimum height and width requirements for these routes to ensure smooth, unobstructed egress. Let's break it down subsection by subsection, with real-world ties to your operations.

1910.36(g)(1): Ceiling Height and Projections

The ceiling of an exit route must be at least 7 feet 6 inches (2.3 m) high. Projections from the ceiling—like pipes, ducts, or lighting—can't dip below 6 feet 8 inches (2.0 m) from the floor.

Picture a chemical mixing area: overhead piping for corrosive fluids often snakes through egress paths. I've audited plants where uninsulated steam lines hung too low, forcing workers in PPE—think bulky respirators and suits—to duck constantly. One near-miss involved a technician clipping his head during a simulated evac, delaying the team by precious seconds. In chemical processing, where helmets are standard, these clearances prevent trips and maintain forward momentum when every breath counts.

1910.36(g)(2): Exit Access Width Minimums

Exit access must be at least 28 inches (71.1 cm) wide at all points. If there's only one exit access to an exit or discharge, that exit and discharge must match or exceed this width.

Chemical facilities often feature narrow corridors flanked by reactors and storage tanks. We once consulted on a site where a single 24-inch path led from a solvent blending room—non-compliant and a lawsuit waiting to happen. During emergencies, like a hydrochloric acid leak, workers need space to pass without bottlenecking. This rule scales up for your high-hazard zones, ensuring duress doesn't compound congestion.

1910.36(g)(3): Accommodating Occupant Load

Exit route width must handle the maximum permitted occupant load per floor. Calculate this via occupant load factors from NFPA 101 or local codes, often 0.1 to 0.2 sq ft per person in industrial settings.

In a bustling chemical plant control room or packaging line, peak shifts might pack 50 souls per floor. Routes narrower than, say, 72 inches (for 100 occupants at 0.2 inches per person minimum) spell disaster. Research from the U.S. Chemical Safety Board highlights egress failures in incidents like the 2010 Tesoro refinery fire, where inadequate widths trapped workers amid flames. We recommend annual load audits, factoring shift overlaps and contractor traffic—vital for compliance and survival.

• Pro Tip: Use 0.15 net sq ft/person for chemical processing floors with fixed equipment.
• Document calculations; OSHA inspectors love transparency.

1910.36(g)(4): No Projections Narrowing the Path

Objects projecting into the route—like pallets, valves, or temporary scaffolding—must not shrink the clear width below minima.

Chemical ops thrive on dense layouts: think protruding sensor arrays on distillation columns or forklift-staged drums in hallways. A playful nudge: don't turn your exit into an obstacle course worthy of American Ninja Warrior. In one facility I assessed, low-hanging electrical boxes reduced a 36-inch path to 22 inches—fixed with rerouting and guards, averting citations. Hazards amplify here; a blocked route during a phosgene release buys seconds for exposure.

OSHA ties these to 29 CFR 1910.37 for general egress, but chemical processing amps the stakes under PSM standards (1910.119). Balance is key: while retrofits cost, incidents cost lives and millions—per BLS data, egress issues factor in 10% of manufacturing fatalities.

Auditing Your Chemical Plant Exits: Action Steps

Start with a laser measure and floor plans. Map occupant loads, flag projections over 6'8", and simulate evacuations in PPE. Reference OSHA's eTool for Exit Routes and NFPA 101 for deeper dives. Individual facilities vary—consult a pro for site-specific tweaks. Compliant exits don't just check boxes; they shield your team in chaos.