Escape routes on construction sites are vital, permanently usable traffic areas for rapid self-rescue and effective assisted rescue. They connect workplaces, break areas and temporary construction states with safe areas and assembly points. In dynamic construction processes, gutting, concrete demolition, cutting operations or handling heavy components continually create new risks and obstructions. This makes a robust, clearly marked escape route concept all the more important—one that reflects the actual construction states and is continuously maintained. In projects where, for example, concrete demolition shears or rock and concrete splitters are used, the targeted creation or keeping clear of passageways can be decisive for gaining seconds in an emergency.
Definition: What is meant by construction site escape route
A construction site escape route is a continuously walkable, sufficiently wide and unobstructed path that guides employees and responders quickly and safely out of danger areas or into safe areas. It includes escape paths, emergency exits, emergency lighting, signage and, where necessary, emergency ladders or crossings. Construction sites are characterized by temporary changes: routing, width, surfaces, fall edges or barriers can change as the work progresses. An escape route is therefore not static; it must be planned, documented, marked and checked on an ongoing basis.
Construction site escape route concept: planning, marking and keeping clear
A sound concept starts with the hazard assessment and the derivation of suitable measures in site setup and traffic route planning. This defines routing, minimum widths, emergency exits, assembly points, emergency lighting, alarm procedures and accessibility for rescue services. Marking is carried out with clear pictograms, highly visible markings and, where required, slip-resistant surfaces and guardrails. Keeping routes clear is ensured organizationally: material storage, hydraulic power packs, hose lines and components are positioned so that they do not constrict escape routes. Changes in the construction sequence are implemented without delay. In areas with demolition or cutting work—for example when using concrete demolition shears—temporary barriers and low-dust methods are advisable to ensure visibility and orientation.
Typical hazards and particularities of temporary construction states
Construction sites change daily. This affects substrates, flatness, lighting and room geometry. Escape routes must reflect this dynamic without losing clarity. The following aspects are particularly relevant in practice:
Impaired visibility, dust and noise
Dust generated by concrete demolition, cutting or splitting can severely impair orientation and visibility. Noise makes communication difficult. Low-dust procedures, extraction and clear acoustic signals improve the usability of escape routes.
Fall and trip hazards
Uneven surfaces, cable ramps, hose lines and loose components are typical trip points. Covers, low-profile cable ramps and regular cleaning are essential.
Work at height, shafts and tunnels
For work in shafts, underground garages or tunnel construction, escape routes are often longer and require secured intermediate areas, emergency lighting and redundant routing. In caverns or galleries, additional escape openings may be necessary.
Sizing, routing and minimum requirements
The specific design of width, length and equipment of escape routes is based on the applicable rules of occupational safety and construction site safety. These requirements must be applied project-specifically and should always be reviewed by qualified planning. The following principles have proven effective:
Path width and cross-section
Escape routes must suit the number of persons and the use. Bottlenecks are to be avoided; doors and passages must open easily in the direction of escape. Temporary works require stable, sure-footed execution.
Routing, emergency exits and assembly points
Routes should be as straight, short and unambiguous as possible. Dead ends are avoided, emergency exits clearly marked and assembly points located in safe, easily accessible areas.
Lighting, slip resistance and weather protection
Where daylight is insufficient, emergency and safety lighting must be provided. Slip-resistant surfaces, especially in wet, icy or slushy conditions, increase safety.
Interfaces with demolition and deconstruction: creating, opening and securing escape routes
In concrete demolition and special deconstruction, escape routes often have to be created or widened first. Depending on the construction state, different tools are used: concrete demolition shears, stone and concrete splitters, combination shears, multi cutters or steel shears. The aim is to create openings while maintaining structural stability, remove obstacles in a targeted manner and avoid weakening the load-bearing structure uncontrollably.
Choice of method and construction state
Splitting methods usually work with low vibration and without sparking. This is advantageous in sensitive areas, for example near adjacent existing components. Cutting and shearing methods are suitable when precise edges and defined removal quantities are required. The choice of method depends on member thickness, reinforcement level, sensitivity to vibration and accessibility.
Cut reinforcement and secure edges
After opening concrete cross-sections, reinforcement must be cleanly cut, for example with a steel shear or suitable cutting tools. Exposed rebar ends are blunted or protected to avoid injury hazards along the escape route.
Dust and guidance measures
Targeted dust suppression, extraction and shielding improve visibility. Clear routing with pictograms and temporary guardrails enhances orientation. Keep clear and keep clean are daily routine tasks.
Application areas with a special focus on escape routes
Escape routes play a central role in all phases and areas. Some fields of application place higher demands on planning and implementation:
Concrete demolition and special deconstruction
With massive members, openings for escape routes require careful structural analysis. The use of concrete demolition shears or stone and concrete splitters enables targeted material removal. Load-bearing members are only worked on after approval and with safeguarding measures.
Strip-out and cutting
In existing buildings, strip-out creates new routing. Slim cutting methods and controlled deconstruction reduce disruptions. Emergency exits must be defined before work starts and kept permanently usable.
Rock excavation and tunnel construction
Underground, escape routes are challenged by longer distances, limited cross-sections and special climate conditions. Additional escape openings, redundant routings and emergency lighting are regularly required. Low-vibration methods support the stability of adjacent areas.
Natural stone extraction
In quarries, differences in height, loose rock layers and weather influences must be considered. Escape routes require safe crossings, clear fall protection and highly visible marking even when dust develops.
Special operations
For operations with elevated risk—such as in contaminated areas or when working on tanks—escape routes must also be decontaminable, well ventilated and passable for responders with specialized equipment.
Emergency organization, evacuation drills and the rescue chain
The best routing plan only works if it is practiced. A robust emergency organization ensures that alarm, evacuation and first aid interlock. Responsibilities are clearly assigned; equipment is known and accessible.
- Alarm: standardized signals, phone numbers, reporting paths
- Assembly points: clearly defined, adequately sized
- First aiders and equipment: dressings, stretchers, extinguishing agents
- Rescue chain: access routes, turning areas, fire department access roads
- Drills: regular walk-throughs, instructions, adjustments
Temporary closures, detours and communication
Construction logistics and escape routes must not block each other. In the event of closures—for example due to cutting or splitting work—detours are prepared, signposted and communicated. After the work is completed, the original routes are restored without delay. Changes are incorporated into the plans and communicated to all parties involved.
Marking and orientation
Directional information, pictograms and color coding support quick decision-making. In dusty environments, additional tactile or acoustic aids are useful.
Documentation in the safety and health plan
Escape routes, responsibilities and measures for keeping them clear are documented in planning and site management. These documents do not replace legal advice but provide an important basis for daily practice.
Material and equipment safety along the escape route
Work equipment must not restrict escape routes. Hydraulic power packs (mobile hydraulic power units), hose lines and accessories are routed to minimize trip hazards. Staging areas for concrete demolition shears, stone and concrete splitters or combination shears are located outside the line of egress, secured against rolling away and tipping over, and readily accessible for rapid removal.
Hose routing and power supply
Hose and cable runs are routed without crossings or over low-profile bridges. Markings improve visibility. Leaks must be remedied immediately; slippery areas must be secured.
Hazardous substances and fire loads
Fire loads must be kept out of escape route areas. Sparks during cutting operations are limited by shielding. Firefighting equipment is available in appropriate numbers and within reach.
Practical guide: establishing, checking and maintaining escape routes
A practical sequence provides a common thread for site management and crews. The following steps have proven their worth and must be adapted to the project:
- Survey: record the construction state, analyze people flows and work areas
- Planning: define routing, widths, emergency exits, lighting and assembly points
- Implementation: create openings, secure edges, install signage
- Keep clear: adapt material logistics, locate staging areas outside escape routes
- Instruct: brief personnel, assign responsibilities
- Drill: test evacuation, document deficiencies and adjust
- Verify: daily walk-through, documented inspections, adjustments when changes occur
Metrics and checks in daily construction practice
Regular, documented inspections increase the availability of escape routes. Concrete measurement and inspection points help with evaluation:
- Clear width and height without installations or stored materials
- Lighting level and functional test of emergency lighting
- Slip resistance, flatness, cleanliness, elimination of leaks
- Legibility and completeness of signage
- Safeguards at edges, openings and crossings
- Availability of firefighting and first-aid equipment along the routes
- Time required for evacuation during drills
Connection to work methods with concrete demolition shears and stone and concrete splitters
When escape routes must pass through massive components, precise methods offer advantages: concrete demolition shears enable controlled removal of concrete with good edge quality, while stone and concrete splitters can prepare openings with low vibration in heavily reinforced cross-sections. In combination with steel shears or multi cutters, reinforcement is cut cleanly. The choice of method depends on structural analysis, environmental conditions and accessibility. Coordination with the structural design and securing the work area are always crucial so that the resulting escape route remains safely walkable over the long term.
Documentation and proof
Plans, walk-through protocols, training records and drill documentation provide evidence that escape routes are planned, installed and functional. These documents are updated as construction progresses and are available to the project team. Clear, concise documentation supports daily implementation and facilitates cooperation with company representatives and emergency services.