Comparing Line Marking Paint Types: Waterborne, Solvent, Thermoplastic | Line Marking Australia Blog

Comparing Line Marking Paint Types: Waterborne, Solvent, Thermoplastic

Last month, a warehouse manager in Dandenong called us with a simple question: "What paint should I use for my loading dock?" Thirty minutes later, we were still talking. The answer depends on traffic volume, surface type, budget, environmental conditions, and how long you want the markings to last.

After completing over 5,000 line marking projects across Australia since 2009, we've developed strong opinions about which materials work best in different situations. Here's our honest breakdown of the three main options.

Waterborne Paint: The Budget-Friendly Workhorse

Waterborne paint is the most commonly used line marking material in Australia. It's affordable, easy to apply, and dries quickly. Most carparks, warehouses, and commercial facilities start with waterborne because the upfront cost is lowest.

Advantages of Waterborne Paint

• Lowest upfront cost (typically 60-70% cheaper than thermoplastic)
• Fast drying time (30-60 minutes in good conditions)
• Low VOC emissions (environmentally friendlier)
• Easy cleanup with water
• Suitable for indoor and outdoor applications

Disadvantages of Waterborne Paint

• Shorter lifespan (18-24 months in normal traffic conditions)
• Less durable against heavy traffic and forklift use
• Susceptible to UV degradation in full sun exposure
• Requires more frequent repainting cycles

A shopping centre in Epping used waterborne paint for their 400-bay carpark. Initial cost was $12,500. After repainting three times over six years at $11,000 each cycle, their total spend hit $45,500. Had they used thermoplastic initially at $38,000, they would have saved $7,500 and avoided three project disruptions.

Solvent-Based Paint: The Industrial Option

Solvent-based paints offer better durability than waterborne but come with environmental and health considerations. They're increasingly restricted in urban areas due to VOC emissions, but remain popular for road marking and heavy industrial applications.

Advantages of Solvent-Based Paint

• Better adhesion on difficult surfaces (oily concrete, asphalt)
• Can be applied in cooler temperatures than waterborne
• More resistant to moisture during application
• Longer lifespan than waterborne (24-36 months typically)

Disadvantages of Solvent-Based Paint

• High VOC emissions (restricted in many councils)
• Strong fumes require PPE and ventilation
• Not suitable for enclosed spaces without extraction
• Cleanup requires solvents (additional cost and disposal)

We rarely recommend solvent-based paint for indoor facilities anymore. The ventilation requirements and health risks outweigh the marginal durability improvement over modern waterborne formulations.

Thermoplastic: The Premium Long-Term Investment

Thermoplastic is heated to around 200°C and applied as a thick, durable layer that fuses to the surface. It's the gold standard for high-traffic environments like shopping centres, hospitals, airports, and major roads.

Advantages of Thermoplastic

• Exceptional durability (5-8 years in high traffic)
• Excellent retroreflectivity for night visibility
• Resistant to chemicals, oil, and fuel spills
• Withstands heavy vehicle and forklift traffic
• Lower total cost of ownership for high-traffic sites

Disadvantages of Thermoplastic

• Higher upfront cost (3-4 times more than waterborne)
• Requires specialised equipment and trained applicators
• Can soften in extreme heat (60°C+ surface temperatures)
• More difficult to remove if changes needed

Which Paint Type Should You Choose?

The decision comes down to traffic volume and budget horizon. Choose waterborne when traffic is under 200 movements daily, budget is limited, or layout changes are likely. Choose thermoplastic when traffic exceeds 400 movements daily, heavy vehicles use the area, or you want to minimise long-term costs.

Real Cost Comparison Over 6 Years

For a 300-bay commercial carpark with 500+ daily movements: Waterborne Route costs $57,000 total (initial $15,000 + 3 repaints). Thermoplastic Route costs $45,000 total with zero repaints. The thermoplastic option saves $12,000 while eliminating three project disruptions.

Get a customised material recommendation for your site

Frequently Asked Questions

Can I mix different paint types in the same carpark?

Absolutely. We often recommend thermoplastic for high-wear areas like main driveways and turning circles, with waterborne for lower-traffic parking bays. This hybrid approach optimises cost while ensuring durability where it matters most.

Does thermoplastic work on asphalt surfaces?

Yes, thermoplastic bonds exceptionally well to asphalt. The heat application creates a mechanical bond with the surface. However, the asphalt must be in good condition first.

What paint type is best for warehouse floors?

For warehouse floors with forklift traffic, we recommend two-pack epoxy or thermoplastic. Standard waterborne paint cannot withstand constant abrasion from hard rubber forklift tyres.