Safety Zones Line Marking

Typical widths are 100mm-150mm for standard zone boundaries, 150mm-200mm for high-risk or restricted zones that need maximum visibility. The width should be proportional to facility size and viewing distances. A massive 40,000m² warehouse might use 200mm boundaries because workers need to see them from 50+ metres away. A smaller 5,000m² facility uses 100mm lines that are perfectly visible at closer distances. High-risk zones (dangerous goods storage, confined space entries, high-voltage areas) often get double lines (two 100mm lines spaced 300mm-500mm apart with diagonal hatching between them) for unmistakable identification. We assess your facility size and recommend appropriate widths during quote stage.

AS 1319:1994 specifies the colour language. Red boundaries indicate danger, prohibition, or restricted access (use for dangerous goods storage, high-voltage areas, confined spaces requiring permits, unauthorized entry zones). Yellow boundaries indicate caution or physical hazards (use for forklift operating zones, areas with overhead loads, uneven surfaces, chemical splash zones). Blue boundaries indicate mandatory actions or PPE requirements (use for hard hat zones, hearing protection zones, safety glasses required areas). Green boundaries indicate safe zones, emergency areas, or first aid locations (use for emergency assembly points, visitor safe zones, first aid stations). White or yellow boundaries work for general operational zones that aren't hazardous (storage zones, staging areas, quality control sections).

Absolutely, and it's essential in most warehouses. Pedestrian walkways (typically marked in yellow) should pass through or around safety zones appropriately. For example, a walkway crossing through a forklift zone should maintain its yellow pedestrian marking but might narrow or have "STOP - LOOK - CROSS" warnings at the intersection. Walkways should never pass through red danger zones (dangerous goods storage, confined spaces) without specific access controls. A distribution centre in Truganina had yellow pedestrian walkways connecting entry points to offices. These passed through several operational zones. We marked each zone with appropriate boundary colours while maintaining the yellow walkway throughout. Workers could follow the safe pedestrian path while seeing which zones they were passing through based on boundary colours.

Blue boundaries (AS 1319 mandatory action colour) around areas requiring specific PPE, plus floor-mounted legends at entry points showing which PPE is required. For example: blue boundary around overhead crane area with "HARD HAT ZONE" painted at entrances, blue boundary around noisy machinery with "HEARING PROTECTION REQUIRED" at entries, blue boundary around chemical areas with "SAFETY GLASSES AND GLOVES REQUIRED" at access points. Some facilities want pictograms showing the required PPE at multiple entry points so workers can't miss them. A manufacturing facility in Altona North had inconsistent PPE compliance. We marked clear zones with blue boundaries and pictogram legends at every entry point. Their safety manager said compliance improved from roughly 70% to 98% because workers could see exactly where PPE was required and which type.

Depends entirely on traffic intensity and materials used. Standard acrylic paint in high-traffic zones needs repainting every 12-18 months. Two-pack epoxy lasts 5-7 years in the same conditions. Thermoplastic can last 8-10 years. But all markings eventually wear, particularly at points where forklifts turn or cross boundaries frequently. We recommend annual inspections to assess condition. Minor wear at crossing points can be touched up without remarking entire zones. Complete failures (markings worn through to concrete) require full removal and remarketing. A cold storage facility in Laverton North marked safety zones with standard paint in 2017. By 2019 they were barely visible. We remarked everything with two-pack epoxy. Five years later those zones still look excellent with just one minor touch-up at high-traffic intersections.

Yes, we work with your current operations and marking systems. We assess existing markings (walkways, forklift lanes, storage zones), identify which safety zones are needed based on hazard assessments, and design zone boundaries that integrate logically with current layouts. This might mean color-coding existing unmarked areas, adding boundary lines to partially defined zones, or incorporating safety zones around new equipment or processes. A warehouse in Campbellfield had basic walkways and storage zones but no formal safety zone system. We conducted a site assessment identifying six hazard areas requiring restricted access, three PPE zones, two emergency assembly points, and one dangerous goods storage area. We marked all zones using appropriate colours while maintaining their existing operational layout. The operations manager said it transformed safety compliance without disrupting their established workflows.