OSHA Egress and Alarm System Updates for Warehouses

Why It Matters

In a high-traffic warehouse with pallets stacked to the ceiling, forklifts buzzing through aisles, and tight turnaround times for inventory—safety can’t be an afterthought. But here’s a hard truth: many warehouses are unknowingly out of compliance with updated OSHA egress and alarm system standards.

The Occupational Safety and Health Administration (OSHA) doesn’t issue changes for fun. When it comes to egress and alarm systems, these updates are directly tied to real-life emergencies—where seconds count, exits matter, and alarm systems are your only shot at alerting workers in sprawling, noisy environments.

If your warehouse hasn’t had its egress paths or alarms reassessed recently, you could be one emergency away from a compliance crisis—or worse, a preventable tragedy.

Let’s break down the updated OSHA egress requirements for warehouses, what’s changed, and how to get your facility up to speed in 2025.

TLDR - Quick Guide

• OSHA’s egress standards (1910.36 and 1910.37) define how warehouse exits must be marked, maintained, and accessible.
• At least two exit routes are required, clearly marked, unobstructed, and sufficient for the building’s occupancy.
• Alarm systems must be capable of being heard and understood throughout the warehouse.
• Battery backup and regular testing of both egress lighting and alarms are now emphasized.
• Compliance isn’t optional—violations lead to hefty fines, shutdowns, and liability risks.

Now let’s dig deeper.

Detailed Breakdown: What's New and What to Watch For

1. Egress Route Clarity and Access

OSHA re-emphasized that exit routes must be permanent, unobstructed, and clearly marked at all times.

For warehouses, that means:

• No pallets, carts, or equipment can block exit paths—even temporarily.
• Aisles must be wide enough for quick movement in case of emergency.
• Any visual obstructions (like stacked inventory or racking systems) must not obscure exit signage.

New guidelines suggest routine audits of egress paths, especially in high-turnover inventory zones.

2. Minimum Number of Exit Routes

Most warehouses are required to have at least two exit routes for emergency egress. However, depending on:

• Occupancy size
• Floor area
• Arrangement of equipment or racking

You may need more. Routes must lead directly outside or to a safe exit discharge area—no detours or locked exit doors.

Tip: Emergency exits equipped with alarms can also serve dual purposes—as both alert systems and code-compliant exits.

3. Exit Signage and Emergency Lighting

Exit signs must now meet stricter visibility standards:

• Clearly illuminated with emergency backup power
• Positioned so they’re visible from any point in the exit path
• Not obscured by equipment, storage, or temporary displays

Additionally, emergency lighting must activate automatically during power failure and remain illuminated for at least 90 minutes—critical in large or windowless warehouse areas.

4. Alarm System Requirements

Warehouses are often loud, expansive, and filled with distractions. OSHA now emphasizes:

• Alarm systems must be audible or visible to all occupants, even in noisy or remote areas.
• Use of strobe lights, vibration alerts, or voice systems for workers with hearing impairments is encouraged.
• Systems must be tested regularly, documented, and maintained by qualified personnel.

Battery backup is now a must-have, ensuring systems still work during power outages or fire incidents that compromise electricity.

5. Documentation and Testing Protocols

New requirements include tighter expectations around:

• Routine testing logs for both alarm and egress lighting systems
• Written emergency action plans that include evacuation and alarm procedures
• Clear training for all warehouse personnel, with updates reviewed at least annually

OSHA inspectors are now more frequently requesting proof of training and system maintenance records, so digital tracking tools are a smart move.

Key Takeaways

• OSHA’s updated egress and alarm system standards are designed to protect warehouse employees in high-risk, high-occupancy environments.
• Exit paths must be clear, well-lit, and supported by visible signage with reliable backup power.
• Alarm systems need to be both loud and smart—able to reach every worker in every corner of the facility.
• Routine testing, documentation, and staff training are essential for staying compliant.
• Falling behind on these updates doesn’t just risk fines—it puts real lives in danger.

FAQs

1. How many exit routes does OSHA require for a warehouse?
Most warehouses must have at least two exit routes, but larger or more complex facilities may require more, based on layout and occupancy.

2. What’s the penalty for blocked egress routes?
OSHA can issue citations and fines for obstructed exit paths. More importantly, blocked routes can endanger lives and delay evacuations in real emergencies.

3. Are visual alarms required in warehouses?
In noisy environments or those with workers who may have hearing impairments, visual alarms such as strobes or flashing lights are recommended to meet accessibility and communication standards.

4. How often should warehouse alarm systems be tested?
Alarm systems should be functionally tested at least annually, with monthly checks on indicators, batteries, and sound levels recommended.

5. What’s the best way to train warehouse employees on egress procedures?
Include egress and alarm response in your emergency action plan, conduct regular drills, and clearly mark all exit paths. Partnering with a fire safety professional ensures training is code-compliant and site-specific.

Not sure if your warehouse meets the latest OSHA egress requirements? AAA Fire Protection can perform a full compliance audit, design evacuation improvements, and update your alarm systems to meet 2025 standards—before the inspectors or emergencies arrive. When safety and speed matter most, we make sure your warehouse is ready to respond.