Exit Routes: Building Safe, Compliant Paths to Safety

Exit routes are critical to workplace safety. In an emergency, clearly marked, code-compliant exits can save lives and reduce injuries by helping employees move quickly to a place of safety. OSHA standard 1910.36 outlines how exit routes must be constructed, maintained, and marked. This guide will help you understand those requirements so you can verify that your facility’s exits are ready when they are needed most.

OSHA defines an exit route as a continuous and unobstructed path of exit travel from any point within a workplace to a place of safety. Every compliant route has three main components: the exit access, the exit, and the exit discharge.

• Exit access: the portion of the path that leads from any occupied area to an exit.
• Exit: the protected, enclosed portion of the route that provides a safe way of travel to the exit discharge.
• Exit discharge: the part of the route that leads directly outside, or to a refuge area with access to the outside.

Most workplaces must have at least two fully functional exits. Multiple exit routes ensure there is still a viable escape path if one route is blocked by smoke, fire, or other hazards. Some facilities will require more than two exits depending on their size, layout, and number of employees. As OSHA notes: More than two exits are required, however, if the number of employees, size of the building, or arrangement of the workplace will not allow employees to evacuate safely.

General Exit Route Requirements

• Exit routes must be a permanent part of the building’s floor plan.
• No explosive or highly flammable materials may be stored along the exit path.
• Exit paths must be kept clear of equipment, storage, or debris that could slow or block egress.
• The egress route must be at least 7 feet 6 inches high and able to support the maximum occupant load for the area it serves. The exit access must be at least 28 inches wide at all points.
• Exit doors must be unlocked from the inside and free of devices that could prevent escape.
• Doors leading to exit routes must have side hinges and must open in the direction of travel toward the exit.
• Exit routes must be able to accommodate the maximum occupant load for each floor they serve.

Lighting and Signage

Employees with normal vision must be able to clearly see exits at all times. Exit areas should be well lit under normal operating conditions, and emergency lighting must be available in case of smoke, power loss, or other low-visibility conditions. Photoluminescent and glow-in-the-dark strips installed along floors, stairs, and walls are an effective way to help workers follow the egress path during an emergency.

Every exit door must be marked with a sign that reads “EXIT.” When possible, exit signs should be standardized throughout the facility in terms of color, shape, and dimensions. The word “EXIT” must be at least 6 inches high with a stroke width of at least 3/4 of an inch, and the sign must be clearly illuminated.

There are two basic illumination options:

• Externally lit signs: must be illuminated by a reliable light source providing at least five foot-candles of illumination on the sign surface.
• Self-luminous or photoluminescent signs: must produce a minimum of 0.6 footlamberts of illumination. Because they do not require electrical power, these signs can be a convenient and resilient choice for many facilities.

If the direction of travel to an exit is not immediately obvious, directional exit signs are required. These signs include the word “EXIT” and an arrow pointing toward the exit route. The line of sight to each exit sign must remain unobstructed at all times.

To avoid confusion during an emergency, doors or passageways that are not exits must be clearly marked “NOT AN EXIT” or clearly labeled with their actual use (for example, “CLOSET” or “BATHROOM”).

Types of Exit Signage

Exit signs are a key part of emergency egress compliance, so it is important to select the right material and format for your environment. Compliant options are widely available; the best choice will depend on whether signs are used indoors or outdoors, the surface they are applied to, and how visible they need to be.

Plastic or aluminum: Rigid signs provide durable, long-term solutions for both indoor and outdoor use. With proper installation, these signs typically provide 5–10 years of performance.

Adhesive: Pressure-sensitive adhesive signs bond directly to doors and other smooth, hard surfaces. They are best suited for indoor use and generally provide 2–5 years of service life.

Projecting: Projecting and flag-mounted signs extend outward from the wall to deliver 180-degree visibility. Because they can be seen from multiple angles and long distances, projecting signs are especially effective for identifying exits and critical emergency locations in busy corridors and production areas.

Exit Construction

Exits must be constructed to perform under fire and smoke conditions. OSHA sets specific fire-resistance requirements to help ensure exits remain usable during an emergency:

• Exits must be separated from the rest of the workplace by fire-resistant materials.
• A one-hour fire-resistance rating is required if the exit connects three stories or less; a two-hour fire-resistance rating is required if the exit connects more than three stories.
• All exit openings must be protected by a self-closing, fire-rated door that remains closed or automatically closes in an emergency.

To prevent confusion, exit enclosures may only contain openings that lead directly to the exit discharge. Storage rooms or other spaces should not open into exit stairwells or exit corridors.

Exit Procedures and Emergency Action Plans

If a workplace has more than 10 employees, a written exit procedure is required. The plan must be kept at the workplace and available for employees to review. Workplaces with 10 or fewer employees may communicate procedures orally, but written plans are still strongly recommended because they provide a clear, consistent reference for training and review.

OSHA also recommends developing a comprehensive Emergency Action Plan (EAP) that incorporates exit route procedures. A complete EAP should include:

• Procedures for reporting fires and other emergencies
• Step-by-step evacuation procedures, including designated routes and assembly areas
• Methods for accounting for all employees after evacuation
• Procedures for employees assigned rescue or medical duties
• A reliable alarm system for fires and other emergencies
• Procedures for employees who may remain briefly behind to shut down critical plant operations, if applicable

Each facility’s EAP should reflect its unique layout, processes, and staffing. By combining clear exit routes, compliant signage, and well-practiced procedures, you can help ensure that your workforce knows exactly where to go and how to get there safely when every second counts.