OSHA and IBC Stair Design Guide

for Safety and Ergonomics

www.lapeyrestair.com
Contents
OSHA Stairs vs IBC Stairs applications 3

Stair components and definitions 6

OSHA and IBC Stair system design criteria 8

Space restricted applications and non-standard stairs 14

Design induced safety factors of stairs 20

Tread depth and safety 22

Other safety factors for applications with space restrictions 31

Ladder vs Stairway safety 34

Stair design for maximum safety and ergonomics 35

OSHA (Occupational Safety and Health Administration) sets and
enforces standards related to working conditions. Its priority is to
reduce the number of safety and health hazards at places of
employment. OSHA-compliant, industrial stairs are intended for
workplace areas that are not publicly accessible.
OSHA requirements: 1910 Subpart D: Walking-Working Surfaces, §1910.25: Stairways

IBC (International Building Code) standards address safety and

health concerns for public buildings. Its priority is to protect public
health and safety. IBC-compliant stairs are intended for areas
accessible to the general public and their design is based on building
type and occupancy.
IBC requirements: Chapter 10: Means of Egress, §1011: Stairways
Typical OSHA stair applications
 Equipment access stairs and platforms
 Crossover stairs and platforms


Operator work platforms and stairs
Catwalk access
PICTURES
 Maintenance access areas

Typical IBC stair applications

 Egress stairs in public places
 Mezzanine stairs
 In-plant office stairs
QUICK CHECK: Which code applies?
 Is the stair accessible only to specific workers as
part of their work operations?
Yes  OSHA stair

 Is the stair accessible to the general public?

Yes  IBC stair

 Is the stair part of the building structure?

Yes  IBC stair
Stair components
and definitions
OSHA Terminology & Definitions IBC Terminology & Definitions
Stair A change in elevation, consisting of one or more risers
Risers and treads that connect one level with another, and includes any landings and
Stairway/Stairs platforms in between those levels. Stairways include standard, spiral, alternating One or more flights of stairs, either exterior or interior, with the
tread-type, and ship stairs Stairway necessary landings and platforms connecting them, to form a
continuous and uninterrupted passage from one level to another

A fixed or permanently installed stairway. Ship, spiral, and alternating tread-type stairs
Standard stairs N/A
are not considered standard stairs

Any equipment, device, or system that prevents an employee from falling from an
Fall Protection
elevation or mitigates the effect of such a fall

A system (including all components) an employer uses to provide protection from N/A
Personal Fall
falling or to safely arrest an employee's fall if one occurs. Examples of personal fall
Protection
protection systems include personal fall arrest systems, positioning systems, and travel
System restraint systems

A building component or a system of building components located at or

A barrier erected along an unprotected or exposed side, edge, or other area of a
Guardrail system Guard near the open sides of elevated walking surfaces that minimizes the
walking-working surface to prevent employees from falling to a lower level
possibility of a fall from the walking surface to a lower level
Handrail A rail used to provide employees with a handhold for support
A horizontal or sloping rail intended for grasping by the hand for
A barrier erected along the exposed or open side of stairways to prevent employees Handrail
Stair rail guidance or support
from falling to a lower level

The upright (vertical) or inclined member of a stair that is located at the back of a stair
Riser tread or platform and connects close to the front edge of the next higher tread, Riser Not specifically defined
platform, or landing

Tread A horizontal member of a stair or stairway, but does not include landings or platforms Tread Not specifically defined
Stair system design criteria
OSHA 1910.28 Employers duty to provide fall protection
1910.28(b)(1)(i) Except as provided elsewhere in this section, the employer
must ensure that each employee on a walking-working surface with an
unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is
protected from falling by one or more of the following:

 1910.28(b)(1)(i)(A) Guardrail systems;

 1910.28(b)(1)(i)(B) Safety net systems; or

 1910.28(b)(1)(i)(C) Personal fall protection systems, such as personal fall

arrest, travel restraint, or positioning systems.
 Design criteria for standard stairs

 Minimum 35” unobstructed width

STAIR WIDTH  Minimum 22” between vertical barriers  Minimum 36” for < 50 occupants; minimum
44” for > 50 occupants

 19.98 to 32.47 degrees (inferred from tread

STAIR ANGLE  30 to 50 degrees from the horizontal
and riser requirements)

STAIR HEIGHT  No maximum  Maximum 12’ height per single run

HEADROOM  Minimum 80” clearance  Minimum 80” clearance

 At least the width of the stair; travel

 At least the width of the stair; minimum
LANDINGS distance equal to or greater than the width
30” deep in the direction of travel
of the stair
 Tread and riser design criteria
INDUSTRIAL USE COMMERCIAL USE

PROJECTED
 Minimum 9.5”  Minimum 11”  Minimum 11”
TREAD DEPTH

RISER HEIGHT  Maximum 9.5”  Maximum 7”  Maximum 7”

Maximum 0.1875” between Maximum 0.1875” between

TREAD/RISER
Must be uniform adjacent treads; maximum adjacent treads; maximum
TOLERANCE
0.375” overall stair run 0.375” overall stair run

Solid risers only for accessible

stairs; open risers with
RISER TYPE Open risers allowed Open risers allowed
maximum 4” opening for all
others 

Open treads allowed; Open treads allowed;

TREAD TYPE Open treads allowed
maximum 1.125” tread gap  maximum 0.5” tread gap 
 Guardrail and handrail requirements
INDUSTRIAL USE COMMERCIAL USE

 36” minimum for

GUARD/STAIR
 42” (± 3”)  42” minimum residential; 42” minimum
RAIL HEIGHT
for all others

HANDRAIL
 36”  34” to 38”  34” to 38”
HEIGHT

GUARDRAIL
 Less than 19” sphere  Less than 21” sphere  Less than 4” sphere
OPENING

One for stairs less than 44”

NUMBER OF
wide; two for stairs more Two Two
HANDRAILS
than 44” wide

TOE BOARD  3.5” minimum height Not required Not required


 OSHA-compliant handrails

Image source: Memorandum From Acting Director Directorate of Enforcement Programs Patrick J. Kapust to Amanda Edens Acting Deputy Assistant Secretary,
September 23, 2019, Subject Correspondence, Enforcement of 29 CFR 1910.29(f)(1)(ii)(B) and 1910.29(f)(1)(iii)(A): Heights of Handrail and Stair Rail Systems
Space restrictions and
non-standard stairs
Applications with space restrictions
HORIZONTAL PROJECTION BY STAIR TYPE
 Non-standard stairs or ladders VERTICAL
STAIR HEIGHT
STEEP-ANGLE
STAIR (68°)
OSHA-COMPLIANT
STANDARD STAIR (45°)
may be used in applications 4' 2'2" 4'3"
where space restrictions prohibit 6' 2'11" 5'10"
the use of standard stairs
8' 3'9" 8'2"

10' 4'7" 9'9"

 Understanding the benefits and 12' 5'4" 12'2"

limitations of these devices is 14' 6'2" 13'9"

key to maximizing safety, 16' 7' 16'1"
efficiency, and comfort 18' 7'10" 17'8"

20' 8'7" 20'1"

For illustrative purposes only; all measurements rounded up to the nearest inch.
 Alternating
tread stair
OSHA Terminology & Definitions IBC Terminology & Definitions
A type of stair consisting of a series of treads that usually A device that has a series of steps between 50 and 70
Alternating are attached to a center support in an alternating manner Alternating degrees from horizontal, usually attached to a center
Ship stair tread-type stair such that users typically do not have both feet on the same tread device support rail in an alternating manner so that the user does
level while using the stair not have both fee on the same level at the same time

A stair that is equipped with treads, stair rails, and open

Ship stair risers, and has a slope that is between 50 and 70 degrees Ships ladder Addressed in the code but not explicitly defined
from the horizontal

Ladder

A stairway having a closed circular form in its plan view

A series of treads attached to a vertical pole in a winding
Spiral stair Stairway, spiral with uniform section-shaped treads attached to and
fashion, usually within a cylindrical space
radiating from a minimum-diameter supporting column

A ladder with rails or individual rungs that is permanently

attached to a structure, building, or equipment; includes Permanent
Fixed ladder Addressed in the code by not explicitly defined
individual-rung ladders but not ship stairs, step bolts, or ladder
Spiral stair manhole steps
Code-compliant uses for alternating tread
and other non-standard stairs
 As access to workspaces
 Applications where a standard stair is not feasible

 As means of egress
 Unoccupied roofs
 Mezzanines up to 250 square feet serving up to five occupants
 Guard towers, observation stations, and control rooms
 Use-case for non-standard stairs
 Standard stairs are used to provide access from one walking-working surface to another when
operations necessitate regular and routine travel between levels, including access to operating
platforms for equipment OSHA §1910.25(b)(7)
 Spiral, ship, or alternating tread-type stairs are used only when the employer can demonstrate that it
is not feasible to provide standard stairs OSHA §1910.25(b)(8)

“OSHA believes that the language in the final rule gives employers greater flexibility (than the previous language.)
The final rule limits the use of non-standard stairs to those circumstances where, based on specific case-by-case
evaluations and demonstrations, it is not possible to use standard stairs.” Federal Register / Vol. 81, No. 223

 Typically, the use-case is space limitations. But, it could be any theoretical reason as
long as the employer can demonstrate that it is not possible to use a standard stair.
 Common space-restricted applications
Small Storage Mezzanines Exterior Roof Access Maintenance Areas Conveyor Equipment Work Platforms

Secondary Egress Equipment Platforms Pits Crossover Stairs Production Equipment

Stair Design Safety Factors
Design-induced risk factors of stairs
 As tread depth becomes narrower than a foot length, missteps become more frequent; shorter treads
give insufficient foot support and cause postural instabilities
 Inconsistent dimensions of tread or rise cause missteps
 Slippery and rough treads cause missteps
 Inappropriate combinations of tread depth and riser height cause awkward walking mode and missteps
 One or two isolated steps may be located in walkways, which provide no cues to their presence
 There may be no graspable, reachable handrail
 There may be a discontinuous handrail
 There may be confusing color patterns on the tread or poor visibility of nosing
 The nosing strip may project above the tread

SOURCE: Fall Prevention and Protection (Human Factors and Ergonomics)

Tread depth and safety
Minimum/maximum stair angles

STANDARD STAIRS 30° to 50° 19.9° to 32.5°

(inferred)

STEEP-ANGLE STAIRS
ALTERNATING
TREAD STAIRS
50° to 70° 50° to 70°

SHIP STAIRS 50° to 70° 63°

(inferred)

LADDERS 60° to 90° Not specified

 Steeper angles stairs require less floor space to install

but also provide less useable tread depth to users
OSHA’s definition of tread depth
 Tread depth is measured
horizontally between the
vertical planes of the foremost
projection of adjacent treads
and at a right angle to the
treads leading edge
Minimum projected tread depths

STANDARD STAIRS 9.5” 11”

ALTERNATING TREAD STAIRS 8.5” 8.5”

NON-STANDARD STAIRS

SPIRAL STAIRS 7.5” 7.5”

SHIP STAIRS 4” 5”

FIXED LADDERS N/A N/A

Standard stairs vs steep-angle stairs

STANDARD STAIRS SHIP STAIRS ALTERNATING TREAD STAIRS

Each foot normally uses only about The unused half tread becomes an The unused half tread is removed to
half of each tread, stepping out and obstacle by reducing the usable provide more tread depth at steep
over the unused section. depth of the tread below. angles.
Missteps increase as tread depth decreases
Ergonomic studies show that missteps and
likelihood of falls increase with stairs that have
less tread depth
 Missteps increase as tread depth
decreases(Templer 1975)
 Treads that are too short force the stair user
to either rest only part of the foot on each
tread or to twist the foot unnaturally; both of
these cases increase the risk of a misstep
(Jackson and Cohen 1995)
 PERCEIVED DIFFICULTY IN DESCENT BY STAIR TYPE
600

The Z-Index Value is a

measure developed by 500 505
Hisao Nagato of the
Ohara Memorial 400
Institute for Science of
Labor in Japan 300

Z Values
200
231
 Z-Index value 182
measures the 146
100
Perceived Difficulty in
Descent of a stairway. 12
0
The higher the index, IBC Stairs Standard OSHA Alternating Tread Spiral Stairs Ship Stairs
the more difficult the Stairs Stairs
stair is to descend

SOURCE: Fall Prevention and Protection (Human Factors and Ergonomics)

Adequate tread depth = more stability and comfort

Entire foot  Half of foot

is stable is unstable

8.5” Minimum
tread depth 4”Minimum
tread depth
 Virginia Polytech Institute study compared
alternating tread stairs to ship stairs
TEST SUBJECTS STRONGLY MORE MISSTEPS ON SHIP
PREFERRED ALTERNATING TREAD STAIRS THAN ALTERNATING TREAD STAIRS:
STAIRS OVER SHIP STAIRS FOR SAFETY AND COMFORT:
73% More overall
missteps

72% Preferred for

safer ascent 129% More missteps when
descending with a load

89% Preferred for more

comfortable ascent
TEST SUBJECTS FELT LESS SAFE AND
LESS COMFORTABLE ON SHIP STAIRS
82% Preferred for
safer descent THAN ALTERNATING TREAD STAIRS:

85% Preferred for more

comfortable descent
64% Felt more likely to
slip/trip on ascent

85% Felt more likely to

slip/trip on descent

Source: Performance, Perceived Safety, and Comfort of the Alternating Tread Stair. Human Factors Engineering Laboratory, Virginia Polytechnic Institute
Other safety factors
for applications with
space restrictions
Tread surfaces and nosing contrast
Design induced risk factors:
Treads with abrasive, non-slip
 Slippery and rough treads cause surfaces and contrast nosings
missteps reduce risk and improve safety
 There may be confusing color
patterns on the tread or poor
visibility of nosing
Provided adequate tread depth, face forward descent
offers safety and ergonomic benefits vs backing down

 Lowers fall risk by improving user-

stability by placing the user’s center of gravity directly
over their feet.
 Lowers chance of musculoskeletal
disorders by neutralizing body posture
 Users can see where they are going to avoid
obstacles or other objects
Ladder vs Stair Safety
Falls from Ladders: User-stability a major
cause of falls

User stability—slip, trip, loss of balance, struck by object, lost

handgrip (55.2% of cases, in Lombardi et al. 2011)

User stability—slip, trip, loss of balance, struck by object (34.7% of

cases, in Lombardi et al. 2011)
Source: Fall Prevention and Protection (Human Factors and Ergonomics) (p. 254). CRC Press. Kindle Edition.
Falls from ladders

19,630
15% 26%
Lost work-day injuries due Fractures
20%
to falls from ladders in 2018 Sprains

23
Bruises/Cuts
14% 25% Soreness
Median days away Other
from work per injury

Falls from ladders account for 20% of all fatal

2017 Updates to General Industry Walking-Working
and lost work-day injuries in general industry Surfaces and Fall Protection Standards

SOURCE: Bureau of Labor Statistics, Workplace Injuries & Illnesses Database

MSDs and ladders The National Institute for Occupational Safety and Health
defines a musculoskeletal disorder (MSD) as a soft-tissue
injury caused by sudden or sustained exposure to repetitive
motion, force, vibration, and awkward positions.

1,680 Diagnosed MSDs due to ladders

resulting in lost work days in 2018 2,500 Lost work-day injuries caused by
overexertion due to ladders in 2018

38 Median days
away from work 45 Median days
away from work

$90,000 Average cost of a MSD-related

worker’s compensation claim 100% Percent of MSDs that
could be prevented

SOURCE: Bureau of Labor Statistics, Workplace Injuries & Illnesses Database; Central for Disease Control
 Stairways are Safer than Ladders
Ladders Stairways

 22,594 average yearly injuries  11,361 average yearly injuries

 149 average yearly fatalities  25 average yearly fatalities
 Estimated $1.1B in workers comp  Estimated $490M in workers comp claims
claims
Stair design for maximum
safety and ergonomics
Stair design for safety and ergonomics
If there are space
If there are no space constraints, choose a
constraints, choose a standard OSHA stair if Choose a ladder only
Is there a space
standard stair with IBC applicable or a non- if there are no other
constraint?
min tread depth, even standard stair with the viable options
if OSHA application most useable tread
depth

 The IBC minimum  The non-standard  Redesigning

tread depth of 11” stair that provides equipment and/or
is the safest option the most useable building layouts to
tread depth is the eliminate ladders is
safest option the safest option
References
 Acting Director Directorate of Enforcement Programs Patrick J. Kapust to Amanda Edens
Acting Deputy Assistant Secretary, September 23, 2019, Subject Correspondence, Enforcement
of 29 CFR 1910.29(f)(1)(ii)(B) and 1910.29(f)(1)(iii)(A): Heights of Handrail and Stair Rail Systems
https://www.osha.gov/laws-regs/standardinterpretations/2019-09-23
 Jackson, P.L. & Cohen, H.H. (1995). An in-depth investigation of 40 stairway accidents
and the stair safety literature. Journal of Safety Research, 26(3), 151-159.
 Templer, J.A. (1992). The staircase: Studies of hazards, falls and safer design.
Cambridge, MA: Massachusetts Institute of Technology.
 Templer, J. A. Stair Shape and Human Movement, doctoral dissertation. New York, NY:
Columbia University (1975)
 Jorna, G.C., Mohageg, M.F., & Snyder, H.L. (1988) Performance, Perceived Safety, and
Comfort of the Alternating Tread Stair. Human Factors Engineering Laboratory, Virginia
Polytechnic Institute
 Fall Prevention and Protection: Principles, Guidelines, and Practices. CRC Press. 2017