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Evacuation vs. Shelter-in-Place: Does Your Workplace Know the Difference?

When an emergency happens, one question can become very important very quickly:

Do we get out, or do we stay inside?

The answer depends on the emergency.

Sometimes the safest choice is to evacuate.

Other times, leaving the building can put employees in greater danger.

That is why a good Emergency Action Plan should address both evacuation and shelter-in-place when appropriate. OSHA specifically recommends that employers consider the conditions that would require evacuation and the conditions under which sheltering in place may be safer.

Knowing the difference can help employees respond faster and with less confusion.

What Does Evacuation Mean?

Evacuation means leaving a building, work area, or other location because remaining there presents a danger.

The goal is to move employees away from the hazard and toward a safe location.

Depending on the emergency, that might mean:

  • Leaving the entire building
  • Leaving only part of a building
  • Moving to another area of the facility
  • Moving to a designated assembly area
  • Moving away from a specific hazard

OSHA’s Emergency Action Plan standard requires covered employers to establish emergency evacuation procedures, including the type of evacuation and exit route assignments.

When Might a Workplace Evacuate?

Evacuation may be appropriate when remaining inside creates a greater risk.

Examples can include:

  • Fire
  • Explosion
  • Structural damage
  • Certain hazardous-material releases
  • Gas leaks
  • Bomb threats
  • Some workplace violence situations
  • Other emergencies that make the building or work area unsafe

The correct response depends on the specific emergency.

For example, OSHA identifies fires, explosions, chemical releases, natural disasters, civil disturbances, and workplace violence among situations that may require evacuation planning.

What Does Shelter-in-Place Mean?

Shelter-in-place means staying inside a designated safe area instead of evacuating.

The idea is simple:

If the danger is outside the building or moving through the surrounding area, remaining inside may provide more protection than going outside.

OSHA describes shelter-in-place as selecting an interior room or rooms within a facility, often with few or no windows, and taking refuge there.

Depending on the emergency, sheltering may involve:

  • Moving employees to designated interior areas
  • Closing doors and windows
  • Limiting outside air entry when appropriate
  • Taking emergency supplies into the shelter area
  • Accounting for employees
  • Monitoring official instructions
  • Remaining there until authorities or designated personnel provide further instructions

When Might Shelter-in-Place Make Sense?

Shelter-in-place may be appropriate when the hazard is outside the building and leaving would increase exposure.

Examples can include:

  • A hazardous chemical release nearby
  • A transportation accident involving hazardous materials
  • Certain severe weather events
  • A dangerous situation outside the facility
  • Some workplace violence or active-threat situations

OSHA gives the example of a hazardous chemical release near a workplace where remaining indoors may be safer than evacuating through the contaminated area.

The key is to understand the hazard.

Staying inside isn’t automatically safer.

The emergency determines the response.

Evacuation vs. Shelter-in-Place

Shelter in place or evacuate

Here’s the simplest way to think about it:

If the danger is…The plan may call for…
Inside the buildingEvacuation may be appropriate
Outside the buildingShelter-in-place may be appropriate
Moving toward or through the facilityFollow the specific emergency plan
A severe weather eventShelter or evacuation may depend on the hazard
A hazardous-material releaseEvacuation or sheltering may depend on the location and type of release
A fire or explosionEvacuation is commonly part of the response
A dangerous intruderEmployees may need to evacuate or shelter depending on circumstances

This isn’t a universal decision table.

The emergency, the workplace, and official instructions all matter.

Your Emergency Action Plan Should Address Both

A strong emergency plan shouldn’t simply say:

“In an emergency, evacuate.”

That’s not enough.

OSHA’s guidance says employers should identify the conditions that require evacuation and the conditions under which shelter-in-place may be better. See here.

Your plan should explain:

  • What situations require evacuation
  • What situations may require shelter-in-place
  • Who can order an evacuation
  • Who can initiate shelter-in-place procedures
  • How employees will be notified
  • Where employees should go
  • How employees will be accounted for
  • What happens to visitors and contractors
  • How employees with special needs will be assisted
  • How employees will receive further instructions

Don’t Use the Same Alarm for Everything

This is an easy detail to overlook.

If your workplace uses alarms or other signals for emergency actions, employees need to understand what those signals mean.

OSHA recommends that different emergency actions use distinguishable notification methods when appropriate. Its shelter-in-place guidance specifically recommends an alert that is distinguishable from the signal used for evacuation.

Think about it this way:

If the alarm goes off, employees shouldn’t have to ask, “What are we supposed to do?”

The signal should trigger a known response.

Where Would Employees Shelter?

“Stay inside” isn’t a complete shelter-in-place plan.

Employees need to know where to go.

A designated shelter area may be:

  • An interior room
  • An area with few or no windows
  • A location away from the hazard
  • An area appropriate for the type of emergency

The best location depends on the emergency.

For example, the ideal shelter location for severe weather may not be the same location used for a chemical release.

That is why emergency planning needs to consider different scenarios.

What Should Be Available in a Shelter Area?

The supplies you need will depend on your workplace and the emergencies you are planning for.

However, consider whether employees may need access to:

  • Emergency communication
  • Flashlights
  • Batteries
  • First aid supplies
  • Drinking water
  • Emergency contact information
  • Employee rosters
  • Basic emergency supplies
  • Appropriate PPE
  • Radios or other communication equipment (NOAA’s Weather Radar and Alerts App – iPhone Android)

For certain shelter-in-place situations, additional supplies may be appropriate.

The goal isn’t to turn a conference room into a survival bunker.

The goal is to make sure employees can safely remain there long enough to receive further instructions.

Account for Everyone

Whether employees evacuate or shelter in place, accountability matters.

Your emergency plan should explain how you will know who is safe.

That can include:

  • Employee rosters
  • Department lists
  • Visitor logs
  • Contractor lists
  • Supervisors
  • Designated accountability personnel

Construction sites may need additional planning because crews and subcontractors can change frequently.

For more information, see our guide to Emergency Preparedness for Construction Sites: What Changes When the Jobsite Changes?

Don’t Forget Visitors and Contractors

Your employees aren’t the only people who may need instructions.

Think about:

  • Visitors
  • Delivery drivers
  • Contractors
  • Temporary workers
  • Customers
  • Vendors

Someone who has never been inside your facility won’t automatically know where to go.

Your emergency procedures should include a way to account for people who aren’t part of your regular workforce.

Employees With Special Needs Need a Plan Too

Emergency planning should consider employees who may need additional assistance.

That could include people with:

  • Mobility limitations
  • Hearing limitations
  • Vision limitations
  • Language barriers
  • Other circumstances that may affect their ability to receive or follow emergency instructions

OSHA specifically recommends considering special-needs employees as part of emergency planning.

The best time to figure this out is before the emergency.

What About Active Threats?

Active-threat situations are a good example of why “always evacuate” isn’t a sufficient emergency plan.

Depending on the circumstances, employees may need to evacuate, shelter, or take other actions based on the immediate threat.

OSHA includes special considerations for evacuation during an active shooter or other dangerous intruder situation in its emergency preparedness guidance.

Employees should receive clear training appropriate to the workplace rather than being expected to make up a response in the moment.

Construction Sites Have an Extra Challenge

Construction sites can make evacuation and shelter planning more complicated.

The safest location can change as the project changes.

Consider:

  • Temporary structures
  • Open floors
  • Excavations
  • Equipment
  • Temporary power
  • Changing access points
  • Changing crews
  • Severe weather exposure
  • Limited enclosed areas

For construction companies, emergency plans should be reviewed as site conditions change.

OSHA’s construction standard, 29 CFR 1926.35, requires employers to establish the types of evacuation to be used in emergency circumstances and to train employees to assist with safe and orderly evacuation.

Practice Both Responses

You can have the best emergency plan in the world.

If nobody has practiced it, employees may still hesitate.

OSHA notes that drills and exercises can help workers understand and remember their roles and responsibilities during emergencies.

Consider practicing different scenarios.

For example:

Scenario 1: Fire in the facility
→ Evacuation

Scenario 2: Hazardous chemical release outside the building
→ Shelter-in-place

Scenario 3: Tornado warning
→ Move to designated shelter

Scenario 4: Emergency affecting one area of the building
→ Partial evacuation or relocation

After each exercise, ask:

What worked?

What didn’t?

What confused people?

Those answers can make your emergency plan better.

A Quick Evacuation vs. Shelter-in-Place Check

Walk through these questions with your team:

Do employees know when they should evacuate?

Do employees know when they may need to shelter in place?

Are evacuation routes clearly identified?

Are shelter locations clearly identified?

Are emergency signals easy to understand?

Can employees receive emergency instructions?

Do you have a way to account for employees?

Are visitors and contractors included?

Have special-needs considerations been addressed?

Are shelter supplies available where needed?

Have employees practiced the procedures?

Has the plan been reviewed since the workplace or jobsite changed?

If several answers are “I’m not sure,” that’s a good indication that your emergency plan deserves another look.

The Goal Is Knowing What to Do Before You Need It

Evacuation and shelter-in-place are not competing safety philosophies.

They are different tools for different emergencies.

The right response depends on the hazard, the workplace, and the information available at the time.

The important part is planning ahead.

Your employees should not have to figure out the plan while the emergency is happening.

They should already know:

Where do I go?

How do I get there?

What am I supposed to do when I get there?

Who tells me when it is safe?

That’s what preparedness looks like.

Take the Checklist to the Workplace

Want to put your emergency preparedness plan to the test?

Our Workplace Emergency Preparedness Checklist gives you a practical way to review evacuation, communication, accountability, emergency supplies, and other important areas.

Download the Workplace Emergency Preparedness Checklist and walk through it with your team.

Keep Building Your Emergency Preparedness Plan

This article is part of our National Preparedness Month workplace safety series.

For the big-picture guide, visit our National Preparedness Month: A Complete Guide to Workplace Emergency Preparedness.

You can also read:

10 Workplace Emergency Preparedness Mistakes That Could Leave Your Team Unprepared

What Does OSHA Require for an Emergency Action Plan?

Spill Happens: What Every Workplace Should Know About Spill Response

Emergency Preparedness for Construction Sites: What Changes When the Jobsite Changes?

Important Note

This article is provided for general educational purposes and is not legal or safety consulting advice. Emergency procedures should be developed for the specific hazards and conditions of your workplace. Always follow instructions from emergency responders and local authorities during an actual emergency.

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Emergency Preparedness for Construction Sites:

What Changes When the Jobsite Changes

Construction sites have one thing that many other workplaces don’t:

They don’t stay the same.

The entrance may move.

A new floor gets added.

Temporary power changes.

Equipment comes and goes.

Crews change.

New subcontractors arrive.

And the hazards can change right along with them.

That creates a unique challenge for emergency preparedness.

A plan that made sense two months ago may not make sense today.

For construction companies, emergency preparedness needs to be more than a document created at the beginning of a project. It needs to keep up with the jobsite.

Why Construction Sites Need a Different Approach

A traditional workplace may have the same exits, assembly area, equipment, and employees every day.

A construction site can change from week to week.

That means emergency planning needs to account for changing conditions.

Some of the challenges can include:

  • Changing access points
  • Temporary stairways and ladders
  • Openings and unfinished floors
  • Temporary electrical systems
  • Heavy equipment
  • Excavation and trenching
  • Scaffolding
  • Cranes and lifts
  • Welding and hot work
  • Flammable materials
  • Chemicals and fuels
  • Changing weather conditions
  • Multiple contractors and subcontractors
  • Employees who may not regularly work at the site

Because the jobsite changes, the emergency plan needs to change with it.

What Does OSHA Say About Construction Emergency Plans?

OSHA’s construction standard, 29 CFR 1926.35, addresses employee emergency action plans.

The standard requires employers to have an emergency action plan for workplaces covered by the requirement. The plan addresses emergency escape procedures, emergency reporting, procedures for employees who remain behind for critical operations, accounting for employees, rescue and medical duties, and designated employees who assist with evacuation.

Construction employers must also designate and train enough people to assist with a safe and orderly emergency evacuation.

OSHA also requires the plan to be reviewed with employees when appropriate, including when employees are initially assigned to the job and when their responsibilities under the plan change.

The important takeaway is simple:

Your construction site needs an emergency plan that employees can actually use.

Start With the Hazards on This Jobsite

Every construction project is different.

So don’t start with a generic emergency plan and assume it covers everything.

Start with the hazards.

Ask:

What could realistically go wrong here?

Depending on the project, that might include:

  • Fire
  • Severe weather
  • Electrical incidents
  • Falls
  • Equipment accidents
  • Trench or excavation emergencies
  • Structural collapse
  • Chemical spills
  • Fuel releases
  • Confined-space emergencies
  • Medical emergencies
  • Utility strikes
  • Heat-related emergencies
  • Workplace violence
  • Flooding
  • Power outages

The list should reflect the actual work being performed.

A high-rise project and a road construction project may have very different emergency risks.

Know How Employees Will Report an Emergency

When something goes wrong, employees shouldn’t have to figure out who to call.

Your plan should clearly explain how emergencies are reported.

Depending on the project, that might include:

  • Calling 911
  • Using a site radio
  • Contacting the superintendent
  • Contacting the safety manager
  • Activating an alarm
  • Using a designated emergency phone

Make sure employees know the procedure.

This is especially important for new workers and subcontractors who may not be familiar with the site.

Keep Emergency Contact Information Current

Construction projects can have a long list of important contacts.

That may include:

  • 911
  • Site superintendent
  • Project manager
  • Safety manager
  • General contractor
  • Property owner
  • Utility companies
  • Emergency medical services
  • Fire department
  • Local emergency management
  • Environmental or hazardous-material response contacts

Don’t let the emergency contact list become another outdated document.

Review it when project contacts change.

Know Where the Emergency Access Points Are

Emergency responders need to be able to find you.

That sounds obvious.

On a construction site, it isn’t always easy.

Temporary roads, gates, equipment, fencing, materials, and changing site conditions can make access difficult.

Make sure employees know:

  • The current site address
  • The best emergency entrance
  • Gate locations
  • Access roads
  • Restricted areas
  • Designated emergency vehicle routes
  • The location of the nearest hospital or medical facility

If the site is large, consider how responders will find the exact area where an incident occurs.

“Come to the construction site” isn’t exactly a great set of directions.

Establish an Assembly Area

Employees need to know where to go after an evacuation.

That means identifying an assembly area that is:

  • Safe from the emergency
  • Accessible
  • Easy to identify
  • Away from emergency vehicle access
  • Large enough for the expected number of people

However, remember that a construction site’s assembly area may need to change.

A location that is safe today may be directly beside tomorrow’s excavation or equipment operation.

Check it as the jobsite changes.

Account for Employees and Subcontractors

Getting everyone out is only half the job.

You also need to know who is missing.

Construction sites may have:

  • General contractor employees
  • Subcontractors
  • Temporary workers
  • Delivery drivers
  • Inspectors
  • Visitors
  • Vendors

That can make accountability challenging.

Your emergency plan should explain how workers will be accounted for and who is responsible for doing it.

Don’t rely entirely on someone yelling, “Is everybody here?”

Use whatever system makes sense for your project.

That could include:

  • Daily sign-in systems
  • Badging
  • Crew rosters
  • Foreman accountability
  • Visitor logs
  • Digital workforce tracking systems

The important thing is that someone owns the process.

Keep Evacuation Routes Usable

A construction site can create new obstacles every day.

Materials get delivered.

Equipment gets parked.

Temporary walls go up.

Stairways change.

Access routes move.

Emergency exits and evacuation paths need to be kept clear and communicated to workers.

Employees should know how to get out from the areas where they are actually working.

That may mean different routes for different phases of the project.

Don’t Forget About Temporary Conditions

Construction sites frequently use temporary systems.

These can include:

  • Temporary electrical systems
  • Temporary stairs
  • Temporary lighting
  • Temporary barriers
  • Temporary access roads
  • Temporary fire protection
  • Temporary structures

Temporary does not mean unimportant.

If a temporary condition changes the way employees evacuate or respond to an emergency, it belongs in the safety conversation.

Severe Weather Can Change Everything

Weather is one of the biggest reasons construction emergency planning needs to stay flexible.

Construction workers may be exposed to:

  • Lightning
  • Tornadoes
  • High winds
  • Heavy rain
  • Flooding
  • Extreme heat
  • Winter weather
  • Hail

A severe-weather plan should explain how employees will receive warnings and where they should go.

For example, an open construction site may not provide adequate shelter during a tornado.

A plan should identify appropriate shelter locations before severe weather arrives.

Don’t wait until the sky turns green to decide where everyone is going.

Excavation and Trench Emergencies

Excavation work creates hazards that require specialized planning.

A trench collapse can happen quickly.

Employees should understand that an unplanned rescue attempt can create additional victims.

Construction emergency planning should identify how excavation emergencies will be reported and how qualified emergency responders will be contacted.

OSHA’s excavation standards contain specific requirements for protective systems, access and egress, inspections, and other excavation hazards. Emergency preparedness should work alongside those requirements rather than replace them.

Never treat a trench rescue like a normal cleanup job.

Falls and Rescue Planning

Falls are another important consideration.

Construction sites may involve:

  • Roof work
  • Leading edges
  • Scaffolds
  • Lifts
  • Ladders
  • Structural steel
  • Openings

A fall-arrest system may save a worker’s life, but it can also create a need for prompt rescue planning.

A worker suspended in a harness after a fall may need assistance.

That means employers should consider rescue procedures when developing their fall protection program rather than simply asking, “Do we have harnesses?”

Fall protection and rescue planning go together.

Fire and Hot Work

Welding, cutting, grinding, roofing, temporary heating, and other hot-work activities can introduce fire hazards.

Construction emergency planning should consider:

  • Fire extinguishers
  • Alarm methods
  • Emergency exits
  • Flammable materials
  • Fuel storage
  • Hot-work procedures
  • Fire watch responsibilities
  • Emergency access for responders

Employees should know what they are expected to do if a fire starts.

They should also know when the appropriate response is to evacuate rather than attempt to extinguish the fire.

Spill Response on Construction Sites

Construction sites can contain fuel, oils, paints, solvents, adhesives, cleaning products, and other materials.

That means spill preparedness belongs in the emergency plan.

Employees should know:

  • What materials are present
  • Where SDS information is available
  • Where spill kits are located
  • What PPE is required
  • How to report a spill
  • When an incidental spill can be safely handled
  • When employees should leave the area and call for help

Not every spill should be handled by the person who happens to be standing closest to it.

For more information, see our guide:

Spill Happens: What Every Workplace Should Know About Spill Response

Medical Emergencies

Construction sites should also have a plan for medical emergencies.

Depending on the project, consider:

  • First aid supplies
  • Trained first-aid personnel
  • AED availability
  • Emergency communication
  • Site access for EMS
  • Address or GPS information
  • Nearest medical facility
  • Procedures for serious injuries

Make sure employees know how to get help quickly.

Minutes matter during a serious injury.

New Workers Need Emergency Information

Construction sites regularly bring new workers onto the project.

That makes orientation important.

A new employee or subcontractor should understand the site’s emergency procedures before starting work.

At a minimum, workers should know:

  • How to report an emergency
  • Emergency exits and routes
  • Assembly locations
  • Alarm signals
  • Emergency contacts
  • First aid locations
  • Severe-weather procedures
  • Site-specific hazards

A five-minute conversation can be much more useful than handing someone a 40-page document and saying, “Read this.”

Subcontractors Need to Be Part of the Plan

A construction site’s emergency plan shouldn’t stop with the general contractor’s employees.

Subcontractors need to understand the site’s emergency procedures too.

Different companies may have different:

  • Radios
  • Communication systems
  • Emergency procedures
  • Training
  • PPE
  • Supervisors

The jobsite still needs one coordinated emergency response.

Make sure subcontractors know how the site’s emergency system works and who is responsible for coordinating the response.

Review the Plan When the Jobsite Changes

This may be the biggest difference between construction emergency preparedness and emergency planning in a permanent facility.

The jobsite changes.

So review the plan when:

  • A new phase of construction begins
  • Site access changes
  • Crews change
  • New hazards are introduced
  • Temporary structures are added
  • Work moves to a different area
  • Evacuation routes change
  • The assembly area changes
  • Emergency contacts change
  • New subcontractors arrive
  • A drill identifies a problem
  • An incident occurs

Don’t wait for the annual safety meeting to discover that the emergency exit is now behind a stack of drywall.

A Quick Construction Emergency Preparedness Check

Take the Checklist to the Jobsite

Emergency preparedness is easier to evaluate when you have something practical to work from.

Our Workplace Emergency Preparedness Checklist gives you a simple way to review your emergency procedures, supplies, communication, evacuation, accountability, and other key areas.

Download the checklist and walk the jobsite with it. You may find a few things that need attention before an emergency puts your plan to the test.

Walk the site and ask:

Does everyone know how to report an emergency?

Is the current site address clearly available?

Can emergency responders easily access the site?

Are evacuation routes current?

Is the assembly area still safe?

Can employees be accounted for?

Are subcontractors included?

Are emergency contacts current?

Are first aid supplies available?

Are spill supplies appropriate for the materials on site?

Are employees prepared for severe weather?

Have fall-rescue needs been considered?

Have excavation and trench emergencies been addressed where applicable?

Has the emergency plan been reviewed since the jobsite changed?

If you answered “I’m not sure” to several of these questions, your emergency plan may need an update.

Emergency Preparedness Is a Moving Target

Construction safety already requires you to think about what can go wrong.

Emergency preparedness takes that thinking one step further.

It asks:

What happens if something goes wrong, and how are we going to respond?

The answer can change as the project changes.

That is why emergency preparedness shouldn’t be treated as a one-time paperwork requirement.

Walk the site.

Talk to the crews.

Review the hazards.

Check the equipment.

Update the plan.

Then do it again when the job changes.

Because on a construction site, the only thing you can count on staying the same is that something will change.

Keep Building Your Emergency Preparedness Plan

This article is part of our National Preparedness Month workplace safety series.

For a broader look at emergency preparedness, visit our National Preparedness Month: A Complete Guide to Workplace Emergency Preparedness.

You can also read:

National Preparedness Month

10 Workplace Emergency Preparedness Mistakes That Could Leave Your Team Unprepared

What Does OSHA Require for an Emergency Action Plan?

Spill Happens: What Every Workplace Should Know About Spill Response

Important Note

This article is provided for general educational purposes and is not legal or safety consulting advice. Construction projects have different hazards and requirements. Employers should review the OSHA standards applicable to their work, project-specific requirements, and emergency procedures with qualified safety professionals.

Sources

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10 Workplace Emergency Preparedness Mistakes That Could Leave Your Team Unprepared

You have an emergency plan. Your employees have been told where to go. There’s a first aid kit somewhere in the building. You’ve got a spill kit on the jobsite. So you’re prepared…right?

Maybe.

The problem with emergency preparedness is that the gaps often don’t become obvious until something goes wrong.

A plan can look perfectly good on paper and still fail when employees don’t know who is responsible for what, an evacuation route has changed, a spill kit isn’t appropriate for the material released, or nobody remembers where the emergency contacts are.

OSHA recommends emergency action planning as a way to help employers and workers respond effectively when an emergency occurs. For employers subject to OSHA’s Emergency Action Plan requirements, the plan must address specific elements including reporting emergencies, evacuation procedures, accountability, rescue or medical duties, and responsible contacts.

Here are 10 common mistakes worth checking before you need your emergency plan.


1. Your Emergency Plan Exists—but Nobody Knows It Exists

One of the easiest mistakes to make is assuming that because an emergency plan exists, employees know what it says.

They may not.

Employees should understand the portions of the plan that apply to them, including how to report an emergency, where to evacuate or shelter, how accountability works, and what responsibilities they may have.

OSHA requires review of applicable emergency action plans with employees at specified points, including when the plan is developed, when responsibilities change, and when the plan changes.

Ask yourself:

If you stopped five employees at random today and asked, “What do you do if the alarm sounds?” would you get five reasonably consistent answers?

If not, there’s work to do.


2. The Plan Is Outdated

This is especially important for construction sites and other workplaces where conditions change.

A new piece of equipment is installed.

A wall is moved.

A chemical is introduced.

An excavation changes access to part of the site.

A new employee takes over an emergency responsibility.

A subcontractor joins the project.

Suddenly, the plan that was accurate six months ago may not accurately describe today’s workplace.

OSHA recommends reviewing and updating emergency plans when changes to layout, equipment, hazardous materials, processes, personnel responsibilities, or hazards affect emergency procedures.

If your workplace changes, your emergency plan should change with it.


3. You Have an Evacuation Route—but No Backup

What happens if the primary exit is blocked?

A fire, structural problem, equipment incident, severe weather event, or other emergency could make a normally usable route unavailable.

Your emergency planning should consider alternate routes and the different types of emergencies that could require evacuation or shelter.

OSHA notes that evacuation procedures should address the different types of emergencies that may occur and the appropriate response for each.

Ask:

“If our normal exit were blocked right now, where would everyone go?”

If the answer is silence, you found a gap.


4. Nobody Has a Reliable Way to Account for Employees

Getting everyone out of a building or away from a hazard is only part of the problem.

How do you know everyone is out?

Your plan should establish a method for accounting for workers after evacuation.

That becomes more complicated when you have:

  • Multiple shifts
  • Contractors
  • Temporary workers
  • Visitors
  • Employees working away from the main facility
  • Large construction sites
  • Multiple crews

OSHA identifies employee accountability after evacuation as a required element of EAPs covered by 29 CFR 1910.38 and 29 CFR 1926.35.

A headcount process that only works when everyone is standing at the front door isn’t much of a process.


5. You Forgot About Contractors and Visitors

Your employees may know the emergency procedures.

But what about the electrician who arrived this morning?

The delivery driver?

The subcontractor working on the other side of the site?

The customer visiting the facility?

The temporary worker who started yesterday?

Emergency planning should account for everyone who may be exposed to the emergency—not just the people who appear on the payroll.

This is especially important on construction sites and multi-employer worksites.

A good question to ask:

“If a visitor arrived five minutes before an emergency, how would we get them to safety?”


6. Your Emergency Equipment Is There—but You Can’t Find It

This one sounds ridiculous until you need something immediately.

Where’s the first aid kit?

Where’s the spill kit?

Where are the emergency lights?

Where are the fire extinguishers?

Where are the radios?

Where’s the eyewash?

Who knows?

OSHA’s emergency preparedness guidance recommends identifying common emergency equipment and assigning responsibility for inventorying and maintaining emergency equipment and supplies.

Emergency equipment should be:

Accessible.

Identifiable.

Appropriate for the hazard.

Maintained.

And, most importantly:

Known to the people who may need it.

Southern Safety Tip

Don’t just ask whether you have an emergency kit.

Ask:

“Could a new employee find it in under two minutes?”

If not, consider improving signage, location, training, or all three.


7. You Bought a Spill Kit—but Didn’t Consider What Could Actually Spill

A spill kit isn’t a universal solution.

The right response equipment depends on the material and the circumstances.

For example, a workplace dealing primarily with oils and fuels may have different spill-response needs than a facility handling corrosive or hazardous chemicals.

Before buying emergency spill supplies, identify:

  • What materials are present?
  • How much could potentially be released?
  • Where are those materials stored or used?
  • What PPE may be needed?
  • Who is trained and authorized to respond?
  • When should employees evacuate instead?
  • When should outside emergency responders be contacted?

Some hazardous-substance emergency response activities can trigger OSHA’s HAZWOPER requirements. Employers should not assume that every employee is authorized or trained to handle a hazardous-material emergency simply because a spill kit is available.

Related Southern Safety resource:

Spill Happens: What Should You Do During a Workplace Spill?

Need spill-response supplies?


8. You’ve Never Actually Practiced the Plan

This may be the biggest one.

A plan can look great in a meeting.

Then the alarm goes off.

Someone asks where everyone is supposed to go.

Someone else can’t hear the alarm.

The assembly area is blocked.

Nobody knows who is counting employees.

And suddenly everyone discovers the plan has some holes.

OSHA recommends practice drills as often as necessary to keep employees prepared and encourages employers to evaluate the strengths and weaknesses of the plan after each drill.

A drill doesn’t have to be elaborate.

Try a scenario such as:

“At 10:15 Tuesday morning, a forklift strikes a container and a spill occurs.”

Then ask:

  • Who reports it?
  • Who sounds the alarm?
  • Who stops nearby work?
  • Who evacuates?
  • Where does everyone go?
  • Who accounts for workers?
  • Who contacts emergency responders?
  • Who is authorized to address the spill?
  • What happens afterward?

You may learn more from a 15-minute exercise than from another hour spent reading the emergency plan.


9. You Prepared for the Emergency—but Not the Aftermath

The immediate danger isn’t necessarily the end of the problem.

After an emergency or drill, ask:

  • Did everyone get accounted for?
  • Did communication work?
  • Were emergency routes accessible?
  • Was the correct equipment available?
  • Were there delays?
  • Were employees confused about their responsibilities?
  • What supplies were used?
  • What needs to be replaced?
  • Does the plan need to be updated?

OSHA recommends evaluating drills, identifying strengths and weaknesses, and improving the plan based on what you learn.

Emergency preparedness should be a cycle:

Plan → Train → Practice → Evaluate → Improve

Then do it again.


10. You Don’t Know What You Don’t Know

This may be the hardest mistake to catch.

Every workplace has hazards that are easy to overlook because they’re part of the normal routine.

A forklift has always operated in that area.

The fuel tank has always been there.

The chemical has always been stored in that room.

The excavation has always been on that side of the site.

The same emergency equipment has been sitting in the same cabinet for years.

Familiar doesn’t mean safe.

Start your emergency preparedness review by walking the workplace with fresh eyes.

Look at:

Environmental risks

Severe weather, flooding, extreme temperatures and other natural hazards.

Operational risks

Equipment failures, vehicle incidents, utility strikes, power failures and machinery emergencies.

Chemical risks

Spills, leaks, releases, incompatible materials and exposure hazards.

Structural risks

Collapse, falling objects, excavation incidents, scaffolding problems and temporary structures.

Fire and life-safety risks

Fire, smoke, explosion, electrical emergencies and gas releases.

OSHA recommends conducting a hazard assessment that considers physical and chemical hazards inside or outside the workplace that could create an emergency, along with the site’s layout, structural features and emergency systems.


The 5-Minute Preparedness Test

Want to see where your plan stands?

Ask your team these five questions:

1. What is the most likely serious emergency we could face?

2. How would you know it was happening?

3. Where would you go?

4. Who is responsible for coordinating the response?

5. What equipment would you need—and where is it?

If your team can answer those questions quickly and consistently, you’re off to a good start.

If they can’t, don’t panic.

You’ve just identified what to work on next.


Ready to Find the Gaps?

Southern Safety Supply can help you identify practical safety and emergency-response equipment for your workplace or jobsite.

That may include:

  • First aid supplies
  • Spill kits and absorbents
  • Safety eyewear
  • Gloves
  • Emergency eyewash
  • High-visibility apparel
  • Barricades and warning products
  • Emergency lighting
  • Jobsite safety equipment
  • Other PPE appropriate to your hazards

And if keeping critical PPE and emergency supplies stocked is a challenge, ask us about Never Out™ Inventory Management.

The goal isn’t to sell you a bigger emergency cabinet.

It’s to help make sure that when something goes wrong, your people aren’t standing around asking, “Where’s the stuff we need?”


Keep Building Your Emergency Preparedness Plan

This article is part of Southern Safety Supply’s Workplace Emergency Preparedness Resource Center.

Continue with:

What Does OSHA Require for an Emergency Action Plan?

Jobsite Emergency Preparedness Checklist

→ Emergency Preparedness for Construction Sites

→ What Should Be in a Workplace Emergency Kit?

→ Spill Happens: What Should You Do During a Workplace Spill?

→ Emergency Drills: Does Your Team Actually Know What to Do?


Sources & Further Reading

This article is provided for general educational purposes and is not a substitute for a site-specific hazard assessment, emergency action plan, training, or applicable federal, state, and local requirements.