Warehouse Zone Line Marking

We typically use colour-coded systems based on AS 1319 standards and warehouse management practices. Common approach: white or yellow for general storage zones, blue for finished goods ready for dispatch, red for hazardous materials, green for quarantine or quality control holds, orange for returned goods or damaged stock awaiting assessment. Each zone gets boundary lines marked on the floor plus large zone identifiers painted at the ends (like "ZONE A - FINISHED GOODS"). A distribution centre in Keysborough had mixed inventory causing constant picking errors. We installed colour-coded zones separating seven product categories. Picking errors dropped 65% within the first month.

Absolutely. Grid systems dramatically improve picking efficiency and inventory accuracy. We mark the floor with alphanumeric codes at each pallet location (A1, A2, A3 in Row A, then B1, B2, B3 in Row B, etc.). These integrate with warehouse management systems so pickers receive exact location codes on their scanners. A logistics facility in Altona North had 800 pallet locations. We installed a complete grid system over two weekends. Their inventory accuracy improved from 87% to 98% because staff could verify they'd picked from the correct location, not just the correct general area.

Two-pack epoxy or thermoplastic. Standard acrylic paint wears through quickly where forklifts cross zone boundaries regularly. We learned this the expensive way at a warehouse in Moorabbin. We marked storage zones with standard paint to save the client money. Within eight months, every forklift crossing point was worn through to concrete. We remarked with two-pack epoxy rated for heavy industrial traffic. Four years later those same boundaries still look excellent. The epoxy costs about 50% more than paint but lasts 5-6 times longer in high-traffic applications.

Typically 75mm-100mm for standard zone boundaries, 150mm for major separation lines or hazardous material zones. The width depends on your facility size and how far away workers are when viewing the lines. A massive 40,000m² distribution centre in Dandenong South used 150mm zone boundaries because workers needed to see them from 50+ metres away. A smaller 5,000m² warehouse used 75mm lines that were perfectly visible at closer distances. Hazardous material zones often get double lines (two 100mm lines spaced 300mm apart) with diagonal hatching between them for maximum visibility.

We mark the floor based on your WMS location codes. You provide us with your zone layout and numbering system (what your software calls each location), and we paint those exact codes on the floor. This keeps physical markings synchronized with digital tracking. Some warehouses want QR codes painted at each zone entrance so workers can scan them for instant zone information on tablets. A cold storage facility in Brooklyn had complex product separation requirements. We marked zones matching their temperature-controlled sections and batch tracking system. The operations manager said it eliminated confusion about where different product batches should be stored.

We create designated parking bays for forklifts, pallet jacks, and other equipment using the same approach as car parking bays. Typically 100mm white or yellow lines outlining the parking area, with equipment symbols or text painted inside ("FORKLIFT PARKING ONLY"). These prevent equipment cluttering aisles or blocking emergency exits when not in use. A warehouse in Sunshine West had forklifts parked randomly throughout the facility, often blocking access to stock or exits. We marked 12 designated parking zones near charging stations. The facility manager said it transformed the appearance from chaotic to organized, and eliminated complaints about blocked access.