Exit Route Dimensions
- Minimum width: 28 inches at any point
- Minimum ceiling height: 7 feet 6 inches
- Exit routes must accommodate maximum occupant load
- Routes cannot decrease in width as they approach exit
- Exit discharge must be at least as wide as exit itself
Lighting & Visibility Requirements
- Exit routes must be adequately lit
- Minimum 1 foot-candle of illumination at floor level
- Emergency lighting required (battery backup)
- Emergency lights must work for at least 90 minutes
- EXIT signs must be illuminated and visible from 100+ feet
Exit Signage Requirements
- Word "EXIT" in letters at least 6 inches high
- Letters must have 3/4 inch stroke width minimum
- Signs must be illuminated (internally or externally)
- Doors that are not exits must be marked (e.g., "NOT AN EXIT")
- Directional signs required where exit direction is not obvious
Exit Door Requirements
- Doors must swing in direction of exit travel
- Doors cannot require special knowledge to open
- Panic hardware required for 50+ occupants
- Doors cannot be locked from inside during occupied hours
- Door hardware must be operable with one hand, no tight grasping
How Many Exits Are Required?
OSHA requires at least two exit routes in most workplaces to ensure one remains available if the other is blocked. More exits may be required based on: occupancy load, floor size, travel distance to exit, and specific hazards present. Exits should be located as far apart as practical to minimize the chance both are blocked.
How Evacuation Maps Support Exit Compliance
Evacuation maps demonstrate exit route compliance by showing: all available exits, primary and secondary routes from each area, exit widths where relevant, and clear paths free of obstructions. Maps help employees identify the nearest exits and alternate routes if primary exits are blocked.
Stay OSHA Compliant — Generate Your Map Now
Upload your floor plan and get a print-ready, compliant evacuation map instantly.
Create Your Free MapExit Route Compliance Facts
OSHA requires all exit routes to be at least 28 inches wide at any point
Battery backup must power emergency lights for at least 90 minutes
EXIT signs must be visible from at least 100 feet away
Exit route obstructions are the 3rd most common OSHA citation
Expert Advice: Exit Route Maintenance
The biggest mistake I see is treating exit route compliance as a one-time setup. Exit routes need weekly inspections. I recommend appointing a "route warden" on each shift who walks every exit path before operations begin. Check for blocked doorways, propped-open fire doors, and stored materials in corridors. A 30-second daily walk-through prevents 90% of the exit violations I cite. Also, test emergency lighting monthly - dead batteries are inexcusable when they're the difference between safe evacuation and tragedy.
Case Study: Warehouse Exit Route Overhaul
Challenge
A 150,000 sq ft distribution center received 4 OSHA citations totaling $62,500 for blocked exits, non-illuminated signs, and exit routes that narrowed below 28 inches due to pallet storage. Operations had gradually encroached on exit paths over 3 years.
Solution
The facility painted bright yellow floor markings designating "no storage" zones around all exit routes, installed motion-sensor emergency lighting, added weekly exit route inspections to the supervisor checklist, and used our tool to create updated evacuation maps showing proper clearance zones.
Result
Follow-up OSHA inspection passed with zero citations. Insurance premiums decreased 12% due to improved safety rating. Employee evacuation drill times improved by 40% with clearly marked and unobstructed routes.