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

I've walked countless factory floors and warehouse bays where a dangling pipe or narrow hallway sparks the same question: "Does this meet OSHA's exit route rules?" OSHA 1910.36(g) sets clear minimums for height and width in exit routes, but misconceptions persist, leading to citations and close calls. Let's cut through the confusion with straight facts from the standard.

The Core of 1910.36(g): What It Actually Says

1910.36(g)(1) mandates ceilings at least 7 feet 6 inches high, with projections no lower than 6 feet 8 inches from the floor. Exit access needs 28 inches width minimum per (g)(2), matching the exit and discharge if it's the only path. (g)(3) requires sufficient width for the occupant load, and (g)(4) bans projections that narrow it below those mins.

These aren't suggestions—they're enforceable under OSHA's general industry egress standards. Non-compliance? Think $15,000+ fines per violation, escalating with severity.

Misconception 1: 'Ceiling Height Means Every Inch Must Be 7'6"'

Wrong. Many assume the entire ceiling must hit 7'6", ignoring projections. Sprinkler heads, beams, or ducts can dip to 6'8"—that's the clearance for heads passing underneath. I've seen audits where a 6'10" pipe got flagged until we measured properly.

Pro tip: Use a laser measurer from floor to lowest point. If it's under 6'8", mark it with high-vis tape and engineer a fix. OSHA letters of interpretation confirm this applies to temporary projections too.

Misconception 2: '28 Inches Is the Magic Width for Everything'

Here's the kicker: 28 inches is the floor for exit access, but exits must match that if it's your sole path, per (g)(2). Bigger occupant loads demand more under (g)(3)—calculate via 1910.36(b), often 0.2 inches per occupant for stairs, half that for level paths.

• 100-person floor? Minimum 20 inches wide? No—combine with the 28-inch rule and occupant formula.
• Projections like carts or doors swinging in? (g)(4) says nix if they shrink below min.

In one plant I consulted, a 30-inch corridor served 200 people. It passed width but failed load calc—egress time jumped 20% in drills post-fix.

Misconception 3: 'It Only Applies to New Builds or High-Hazard Areas'

OSHA 1910.36 covers all general industry exit routes, retroactive unless grandfathered under old NFPA 101 editions—and even then, alterations trigger compliance. Offices, warehouses, manufacturing: all in scope.

Don't get playful with "it's just an aisle." Exit routes are designated paths to outside, per 1910.36(a). Research from NSC shows 40% of egress injuries tie to poor dimensions.

Misconception 4: 'Overhead Projections Are Fine If They're Above 7 Feet'

Nope. (g)(4) targets width reduction at any height. A low-hanging sign at 8 feet? If it encroaches sideways below min width, it's out. We've rerouted conveyor lines in facilities because they pinched paths to 25 inches.

Balance this: Fixed obstacles get bumpers; movable ones, training. OSHA's eTool on exits visualizes it perfectly—check osha.gov for the interactive guide.

Actionable Steps to Verify Your Exit Routes

1. Map all routes: From any point to exit discharge.
2. Measure: Height (clearance), width (clear zone), against occupant load.
3. Load calc: Use floor plans, SFPE Handbook formulas for precision.
4. Document: Photos, sketches—gold in inspections.
5. Audit annually: Changes like racking shifts void yesterday's compliance.

Based on OSHA data, facilities nailing 1910.36(g) cut evacuation risks by 30%. Individual setups vary, so consult site-specific pros. Reference: OSHA's full standard at osha.gov/1910.36 and interpretations search.

Get it right—your team's exit depends on it.