In the heart of Welshpool’s industrial precinct, a medium-sized manufacturing plant was one misstep away from a serious workplace injury. Over the years, the site had expanded organically, with new machinery added and workstations relocated, but the floor safety markings had not been maintained. The result? A cluttered, confusing environment where pedestrian walkways bled into forklift zones and emergency exits were half-obscured beneath grime and faded paint.
This scenario is more common than you think. Across Western Australia, regulators are tightening their stance on floor safety compliance. In 2024 alone, WorkSafe WA issued over 170 improvement notices directly related to floor marking violations. With enforcement on the rise, factory owners like John (a third-generation operator of a metal fabrication business) face growing pressure to modernise or risk serious legal and financial fallout.
John wasn’t waiting for an accident to happen. He contacted Spray Pave Perth with a brief: transform the safety and navigability of his factory floor, without interrupting production. The job had to be done right, done fast and done to spec.
John's factory employs 20 staff and operates multiple forklifts across a tight, equipment-heavy floor plan. Over time, the epoxy and paint marking the facility's safe zones had faded beyond recognition. In some areas, lines were barely visible. In others, workers had resorted to using chalk or tape to indicate hazardous spots—quick fixes that wore away within days.
The lack of clarity wasn’t just inefficient—it was dangerous.
Two near misses in the past 12 months involved forklift operators narrowly avoiding pedestrian staff near the sheet metal station. Insurers flagged the factory during a routine audit, warning of potential liability issues and increased premiums. John was informed he could face penalties of up to $25,000 under Western Australia's Occupational Safety and Health Regulations if corrective action isn’t taken.
It is not just the fines I was worried about, John says. It is the idea of someone getting hurt—or worse—on my watch.”
This was no longer a maintenance issue. It was a business risk with real financial and human consequences.
When the lines disappear, systems break down. People guess where it’s safe to walk, forklifts lose their lanes—it becomes chaos, said a senior engineer from Spray Pave Perth.
Epoxy coating isn’t just paint—it’s a high-performance material engineered to resist abrasion, chemicals and heavy machinery. It remains visible even under heavy use said their compliance specialist
These aren’t cosmetic fixes—they’re industrial safety upgrades.
Spray Pave Perth approached the job with the precision of a construction-grade risk remediation project. Here’s how they executed it:
1. On-Site Risk Audit
Their team conducted a detailed walkthrough with John and his foreman. They mapped foot traffic, identified high-risk machinery zones and assessed intersections between people and moving equipment.
2. Surface Prep
Mechanical grinders and vacuum dust extraction were used to remove faded markings and floor debris. The surface was then profiled to ensure strong adhesion of the epoxy coating, even in high-traffic zones.
3. Priming for Longevity
A two-part epoxy primer was applied across all forklift routes and around hazardous equipment. This formed a durable chemical bond between the substrate and topcoat. It was crucial for ensuring long-lasting performance.
4. Precision Marking
Spray Pave Perth applied high-visibility epoxy in yellow and white. The line widths matched Western Australian industrial standards with 100mm for pedestrian walkways and 150mm for vehicle paths. Anti-slip aggregates were added to improve worker safety.
Special stencilling was used to designate emergency exit routes, restricted zones and load-bearing areas.
5. Fast Curing Process
Thanks to winter temperatures and advanced epoxy formulations, the coatings cured in under eight hours. Work resumed the next morning without operational delay.
6. Final Testing and QA
Adhesion and thickness tests confirmed the coating met ISO 2178 standards. Reflectivity and skid resistance were also checked.
What Changed: Measurable Gains in Safety and Efficiency
Within days of the upgrade, John’s team reported improved workflow. Forklift drivers no longer hesitated. Walkways were respected. Machine operators felt safer.
The measurable results:
This case demonstrates that proactive investment in floor safety yields both economic benefits and improved workplace safety. For factories, depots and warehouses, line marking is no longer just a visual aid—it’s a compliance necessity.
Too many businesses cut corners with cheap paint that flakes off in months. You end up doing it twice—and risking a fine or injury in between, says the Spray Pave Perth lead technician.
What’s next? Industry standards are shifting toward full-colour zoning: red for danger, green for pedestrian paths, blue for service zones. UV-resistant coatings and glow-in-the-dark markings are already being tested for night-shift operations.
John, for one, isn’t hesitating.
This upgrade changed how we work. I’ll be rolling this out across both of our other sites within the year.
Testimonial
I used to lose sleep over safety reports. Now we’ve got a factory floor that’s clean, clear and compliant. The team feels it too. Everyone is working more efficiently, quickly and safely.
— John, Factory Owner, Welshpool
The Bottom Line: Act Before Safety Becomes a Liability
Unclear floor markings are more than a maintenance oversight—they're a silent liability. If your site lacks durable, regulation-compliant line marking, the risk isn’t hypothetical. It’s real and it’s growing.
Spray Pave Perth’s epoxy floor line solutions are engineered for high-demand industrial environments. They comply with the latest WA regulations, resist damage and improve visibility where it matters most.
Don’t wait for a notice or an injury to act.
Key Takeaways: What Every Site Manager Should Know
Turn Risk Into Readiness
Faded floor lines are a silent risk. Don’t wait for an accident or compliance notice.
Get industrial-grade line marking that protects your staff, streamlines operations and meets every standard.
Book your site assessment with Spray Pave Perth today.
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