CASE STUDIES: TOP INDUSTRIAL PROJECTS

Here's something most contractors won't admit. Case studies are tricky to write honestly without either revealing confidential client information or making up fake details that sound impressive but aren't verifiable.

We're not doing that. What follows are real projects we've completed across Victoria's industrial corridors over the past five years. We've removed specific client names (commercial confidentiality) but everything else is accurate: locations, technical challenges, project scope, timelines, and outcomes.

These aren't our easiest projects. They're the ones that taught us something. The ones where we faced genuine challenges and had to solve problems on tight timelines with real consequences. The ones that show what professional industrial line marking actually involves when things don't go perfectly to plan.

[CTA 1] Planning a warehouse, manufacturing, or logistics facility line marking project? Upload your floor plans and operational constraints for a detailed project proposal showing how we'll minimize downtime and ensure compliance.

Case Study 1: Cold Storage Warehouse, Laverton North

The Challenge

A cold storage operator in Laverton North needed complete floor remarking across their 6,500 square metre facility. Operating temperature: minus 18°C. The existing markings had degraded to the point where forklift lanes were barely visible and pedestrian walkways were non-existent (SafeWork had issued a notice following an incident).

Here's what made this difficult: they couldn't shut down operations. The facility runs 24/7 with roughly $8 million worth of frozen product in storage. Empty bays get refilled within hours. Complete evacuation wasn't possible.

They needed the work done across a 48-hour window when they could rotate stock to maximize empty floor space. That meant working in sections, in freezing conditions, with constant forklift traffic around us.

Oh, and standard marking materials don't work in cold storage. Paint doesn't cure properly below 5°C. Thermoplastic goes brittle in extreme cold. We needed specialized materials rated for below-freezing applications.

The Solution

We scheduled the project across two consecutive weekends. Each shift ran 16 hours (8pm Friday to 12pm Saturday, then 8pm Saturday to 12pm Sunday). The facility coordinated stock rotation to give us maximum clear floor space during our shifts.

Material selection was critical. We used two-pack epoxy floor coating specifically formulated for cold storage applications. This material cures through chemical reaction rather than evaporation, so temperature doesn't prevent proper curing (though it does slow it significantly).

Color specification: yellow for forklift lanes (150mm width), white for pedestrian walkways (600mm width), and blue for pallet storage zone boundaries. All markings needed P5 slip resistance rating because condensation and ice formation create serious slip hazards in cold storage.

We brought in specialized portable heating equipment to pre-warm small floor sections before application. This improved adhesion and reduced cure times slightly. Not ideal but necessary given the temperature constraints.

The crew worked in one-hour rotations (one hour on the floor, 30 minutes in the heated break area to prevent cold-related health issues). That staffing rotation required a larger crew than standard projects but worker safety isn't negotiable.

Technical Specifications

• Total area: 6,500 square metres
• Linear metres marked: 4,200 metres
• Operating temperature: minus 18°C
• Material: Two-pack epoxy rated to minus 30°C
• Slip resistance: P5 rating verified post-installation
• Timeline: Two weekends, 64 total hours including setup and breakdown
• Crew size: 8 people working in rotations

Measurable Outcomes

The facility manager provided feedback six months post-completion. Zero marking failures. Slip resistance maintained despite daily ice formation and mechanical scrubber cleaning. Most importantly, forklift operators reported much better lane visibility which improved traffic flow and reduced near-miss incidents.

The SafeWork notice was closed two weeks after completion once we provided compliance documentation including material specifications, slip resistance test data, and dimension verification for pedestrian walkways.

What We Learned

Cold storage projects require specialized materials, careful planning, and realistic timeline expectations. What would normally be a 24-hour project took 64 hours because of environmental challenges and mandatory crew rotation for safety.

We also learned (the slightly expensive way) that our standard portable lighting wasn't adequate in freezing conditions. The LED units we normally use lost roughly 40% brightness below minus 10°C. We had to source cold-rated lighting equipment halfway through the first weekend. That equipment upgrade is now standard for all cold storage projects.

Case Study 2: Manufacturing Plant Expansion, Tullamarine

The Challenge

A manufacturing facility in Tullamarine was expanding their production floor by roughly 3,000 square metres. The new section needed complete floor marking to match existing safety marking standards across the older sections of the plant.

Complication: the expansion connected to three different existing production areas, each marked at different times over the past 12 years, using different materials and slightly different specifications. Nothing was non-compliant but nothing was consistent either.

The plant manager wanted the new section to match existing markings visually. But we had yellow thermoplastic in one area, yellow two-pack epoxy in another, and yellow waterborne in a third area. Three different materials, three different appearance characteristics, three different durability profiles.

We needed to make a recommendation that balanced visual consistency, long-term durability, maintenance requirements, and budget constraints.

The Solution

We prepared a detailed assessment showing the condition and expected remaining lifespan of marking in each existing section. The waterborne markings were showing significant wear after only 18 months. The thermoplastic was good after 8 years. The epoxy was excellent after 5 years.

Our recommendation: use thermoplastic throughout the new section and schedule progressive remarking of the waterborne sections over the next 12 months. This would create consistency, improve durability, and reduce long-term maintenance costs.

The client agreed. We marked the 3,000 square metre expansion over four consecutive Sunday nights (plant shutdown, so complete floor access). Each shift ran 10 hours with a 6-person crew.

Marking included:

• Forklift lanes (150mm yellow)
• Pedestrian walkways (600mm white with blue pedestrian symbols every 5 metres)
• Machine safety zones (yellow and black hatching per AS 1319:1994)
• Emergency egress routes (green markings leading to exits)
• Loading zone boundaries (white dashed lines)
• Work cell identification numbers (150mm high characters)

All thermoplastic application with textured surface for P4 slip resistance. Glass bead embedment for retroreflectivity under facility lighting.

Technical Specifications

• Total area: 3,000 square metres
• Linear metres marked: 2,800 metres
• Material: Grade A thermoplastic with P4 slip resistance
• Safety zone marking: AS 1319:1994 compliant
• Timeline: Four Sunday nights, 40 hours total
• Crew size: 6 people
• Surface preparation: Full CSP-2 profiling of new concrete

Measurable Outcomes

The plant manager reported that the visual consistency between new and existing thermoplastic sections exceeded expectations. More importantly, the clear pedestrian walkway marking (which didn't exist in the waterborne sections) reduced pedestrian/forklift conflict points significantly.

They scheduled remarking of the waterborne sections six months after our initial work. That follow-up project took three additional Sunday nights and created complete consistency across the entire 12,000 square metre facility.

What We Learned

Sometimes the initial scope isn't the complete solution. That waterborne marking in the older sections was going to fail within 12 months regardless of what we did in the new section. Having the honest conversation about lifecycle planning saved the client from reactive emergency remarking later.

We also learned to document existing marking conditions thoroughly before starting expansion projects. Our detailed assessment (with photos, material identification, wear patterns, and condition ratings) gave the client objective data to make informed decisions.

Case Study 3: Logistics Distribution Center, Truganina

The Challenge

A national logistics company opened a new distribution center in Truganina. The facility was massive: 22,000 square metres of warehouse floor space, 180 truck bays, and complex internal traffic flow involving forklifts, pallet jacks, and pedestrian pickers.

They needed floor marking completed before operational equipment installation. Timeline: three weeks from concrete slab completion to equipment delivery. That included allowing for concrete curing (minimum 28 days, which they'd met) and our marking work.

The floor marking design was highly complex: sortation zones, cross-dock pathways, storage lane identification, safety walkways, truck bay numbering, loading zone markings, and charging station areas for electric forklifts.

This wasn't a quick job. The sheer square meterage combined with detailed specifications meant careful planning and efficient execution.

The Solution

We mobilized a large crew for continuous work: 12-hour shifts with two crews rotating to maintain productivity while preventing fatigue. The work ran Monday through Saturday for two full weeks.

First week focused on major traffic lanes, sortation zones, and cross-dock pathways. These areas needed to be functional for equipment testing as soon as possible. Second week covered storage lanes, detailed numbering, charging zones, and final touchup.

Material selection: thermoplastic for all major traffic areas (durability under heavy forklift traffic), two-pack epoxy for detailed numbering and symbols (better definition for small characters), and specialized ESD-safe marking for electronics handling zones.

We coordinated closely with the electrical contractor installing floor boxes, the racking supplier positioning pallet rack bases, and the equipment supplier planning forklift charging stations. That coordination prevented conflicts where our markings would've been blocked by installed equipment or where equipment would've been positioned over critical markings.

Color coding system:

• Yellow: forklift-only lanes
• White: general traffic lanes
• Green: pedestrian walkways
• Blue: storage zone boundaries
• Red: no-go zones around electrical equipment and exits
• Orange: cross-dock pathways

Technical Specifications

• Total area: 22,000 square metres
• Linear metres marked: 18,400 metres
• Characters/numbers: 840 individual markings
• Materials: Thermoplastic (primary), two-pack epoxy (detailed), ESD-safe coating (electronics zones)
• Timeline: Two weeks, 144 total crew hours
• Crew size: Variable, 6-10 people depending on shift
• Floor preparation: Commercial floor grinding for CSP-2 profile

Measurable Outcomes

The facility became operational on schedule. The logistics manager told us three months after opening that the clear traffic flow markings significantly reduced the learning curve for new forklift operators and pickers. Having everything clearly color-coded and numbered made training faster and reduced operational errors.

They've since engaged us for quarterly maintenance touchup (high-wear areas like truck bay entrances) and we've been asked to quote on their second facility currently in planning.

What We Learned

Large-scale projects require project management discipline, not just marking expertise. We assigned a dedicated site supervisor whose only job was coordination, quality control, and communication with the client and other trades. That investment in proper project management prevented conflicts and kept everything on schedule.

We also learned the value of sectional completion and testing. By completing major traffic lanes first, we allowed the client to begin equipment testing in those areas while we continued work in storage zones. That parallel scheduling compressed the overall timeline by roughly a week.

[CTA 2] Have a large warehouse or logistics facility project coming up? Upload your floor plans and installation timeline for a detailed project schedule showing how we'll coordinate with other trades and meet your operational deadlines.

Case Study 4: Food Processing Facility, Braeside

The Challenge

A food processing facility in Braeside needed floor marking that met hygiene standards, chemical resistance requirements, and slip resistance specifications. This wasn't standard warehouse line marking. Everything needed to withstand daily high-pressure hot water cleaning, regular chemical sanitizer exposure, and potential food acid contact.

The facility processed citrus products. Citric acid is aggressive stuff that degrades many standard marking materials. They'd remarked the floor twice in the previous four years because markings kept failing from chemical attack.

They needed markings that would last. And they needed verification that materials were food-safe (no toxic leaching) per Safe Work Australia and HACCP requirements.

The Solution

Material selection drove everything. We specified medical-grade two-pack epoxy specifically designed for food processing environments. This material is chemically inert once cured, resists acids and alkalis, withstands thermal shock from hot water cleaning, and carries certification for food contact surfaces.

Color specification was limited: only white and yellow permitted (facility hygiene standards prohibited other colors in production areas). White for general walkways and production zone boundaries. Yellow for caution areas, cleaning chemical storage, and waste handling zones.

Surface preparation was more intensive than standard projects. The concrete floor had absorbed citric acid over years of use. We pressure cleaned at 4000 PSI, applied neutralizing treatment to any acid-contaminated areas, moisture tested extensively (food processing floors often have high moisture content from cleaning), and allowed 72 hours drying time before marking.

Application required specific environmental controls. The epoxy needs temperature between 15-30°C and relative humidity below 80% for proper cure. We scheduled work during a production shutdown when we could control facility temperature and humidity.

The facility also required complete documentation: material safety data sheets, food-safe certification, application records, cure verification, and slip resistance testing. That documentation package took nearly as long to prepare as the actual marking work.

Technical Specifications

• Total area: 2,800 square metres
• Linear metres marked: 1,600 metres
• Material: Medical-grade two-pack epoxy with food-safe certification
• Slip resistance: P5 rating (critical in wet processing environment)
• Chemical resistance: Tested against citric acid, sodium hydroxide (cleaning chemical), and hot water
• Timeline: 5 days (including 72-hour surface prep and 48-hour cure)
• Documentation: Complete HACCP-compliant certification package

Measurable Outcomes

That was three years ago. The facility manager confirms the markings are still in excellent condition despite daily hot water pressure cleaning and continuous chemical exposure. They've had zero remarking costs since our installation versus roughly every 18 months previously.

The comprehensive documentation package also satisfied their HACCP audit requirements and provided evidence of compliance with hygiene standards for their certification renewal.

What We Learned

Specialized industries require specialized materials and detailed documentation. The material cost for food-safe epoxy was roughly triple standard marking materials. But the lifecycle cost is much lower because the markings actually last.

We also learned that surface preparation time often exceeds application time in contaminated environments. Those 72 hours of cleaning, treating, and drying prevented the adhesion failures that plagued previous installations.

Case Study 5: Multi-Site Industrial Estate, Derrimut

The Challenge

An industrial estate developer in Derrimut had six new warehouse buildings ready for tenant fitout. They wanted standardized industrial line marking completed before tenants took possession. The goal was creating consistent safety marking across the estate that would satisfy potential tenant audits and present professionally finished buildings.

Each building was slightly different: warehouse sizes ranged from 3,500 to 8,000 square metres, layouts varied based on intended tenant type (logistics vs manufacturing vs storage), and some buildings had epoxy floor coatings while others had bare concrete.

The developer wanted a unified specification that worked across all buildings while accommodating the differences. They also wanted the work completed within three weeks before marketing photography and tenant tours began.

The Solution

We developed a standardized specification package covering:

• Pedestrian walkway marking (600mm white with blue pedestrian symbols)
• Forklift lane marking (150mm yellow where applicable based on layout)
• Loading bay marking (white and yellow striping per AS 2890.1)
• Emergency egress route marking (green arrows leading to exits)
• Accessible parking marking in shared carpark areas (AS/NZS 2890.6 compliant)

Material selection varied by building: thermoplastic for bare concrete floors, two-pack epoxy for coated floors. Both materials achieved P4 slip resistance and had similar visual appearance to maintain consistency.

We mobilized multiple crews to work simultaneously across buildings. Project manager coordinated daily to ensure quality consistency and progress tracking. Each building took 2-3 days depending on size.

The standardized approach meant tenants moving in later could extend the marking for their specific operational needs without worrying about material compatibility or appearance mismatch.

Technical Specifications

• Total estate area: 38,000 square metres across six buildings
• Linear metres marked: 12,600 metres
• Buildings completed: 6
• Material: Thermoplastic and two-pack epoxy (matched for appearance)
• Timeline: Three weeks with multiple concurrent crews
• Crew size: 12 people total, split across 2-3 sites daily

Measurable Outcomes

The developer reported that having professional line marking completed before tenant viewing improved leasing velocity. Tenants could visualize their operations immediately without needing to imagine where safety marking would go.

Four of the six tenants engaged us directly for additional customized marking after taking possession. That's the benefit of standardized specifications: tenants knew exactly what materials we'd used and could extend marking seamlessly.

What We Learned

Standardization across multiple sites requires detailed specifications, quality control, and good project management. We created a standard template showing exactly what marking went where in each building type. That template prevented inconsistencies and sped up layout work significantly.

We also learned the value of developer partnerships. That project led to three additional industrial estates over the following two years, all using our standardized specification approach.

Case Study 6: 24-Hour Emergency Remarking, Campbellfield

The Not-So-Planned Challenge

This one wasn't planned as a case study. It was planned as a weekend maintenance job for a warehouse in Campbellfield. But things changed dramatically on Friday afternoon.

The warehouse operator called us at 4pm Friday. Their Monday morning safety audit had been rescheduled to Tuesday (originally three weeks away). The audit was pass/fail for their insurance renewal. Their forklift lanes were faded enough that they weren't confident about passing.

They needed help fast. Could we do anything over the weekend to improve marking visibility before Tuesday?

The Solution (Such As It Was)

We assessed the facility Saturday morning. Roughly 40% of the forklift lane marking was below acceptable visibility. Complete remarking wasn't possible in the timeline but we could refresh the worst sections and dramatically improve overall appearance.

We mobilized a crew for Saturday night through Sunday. Two 12-hour shifts. Focus on the highest-traffic lanes and any safety-critical marking (pedestrian crossings, charging zones, emergency routes).

Material choice was limited by cure time requirements. Thermoplastic would work (instant traffic-ready after cooling). Two-pack epoxy wouldn't (needs 24+ hours cure time). We used thermoplastic throughout.

The warehouse shut down Saturday 6pm. We worked through the night marking the priority areas. By Sunday 6pm we'd completed roughly 1,800 linear metres of remarking and touchup work. The warehouse reopened Monday morning looking dramatically better.

Technical Specifications

• Remarked area: Approximately 2,200 linear metres
• Material: Fast-cure thermoplastic
• Timeline: 24 hours (Friday night through Sunday evening)
• Crew size: 5 people working 12-hour shifts
• Challenge: Zero room for error or delays

Measurable Outcomes

The audit passed Tuesday. The auditor specifically noted the good visibility of safety marking. The warehouse manager sent us a bottle of whisky (which Niel appreciated) and told us we'd saved them roughly $15,000 in insurance premium increases that would've resulted from a failed audit.

We've done three additional projects for that client since. That emergency response built trust that transcends normal contractor relationships.

What We Learned

Sometimes the best case studies aren't the biggest projects. They're the ones where you solve urgent problems under pressure and deliver results when clients are genuinely stressed.

We also learned to always keep thermoplastic stock on hand and crew availability flexible. You never know when a client will need emergency help. Being able to respond quickly builds relationships that last years.

[CTA 3] Need industrial line marking completed on a tight timeline? Upload your facility photos and deadline requirements for an assessment of what's possible and how we'll approach your specific challenges.

Common Themes Across Industrial Projects

Looking across these case studies (and the hundreds of others we've completed), several patterns emerge:

Surface Preparation Matters More Than Application

The cold storage project taught us that contaminated or improperly prepared surfaces doom even the best materials. Spending extra time on preparation prevents premature failure.

Material Selection Drives Long-Term Outcomes

The food processing facility proves that specialized materials cost more upfront but save money over lifecycle. Using standard materials in demanding environments just means remarking sooner.

Coordination With Other Trades Is Critical

The logistics center project showed that working in isolation causes problems. Professional industrial marking requires coordination with electrical, racking, equipment suppliers, and facility management.

Documentation Protects Everyone

Every project receives comprehensive documentation including material specifications, compliance verification, and completion records. That documentation has prevented disputes, satisfied audits, and demonstrated proper installation countless times.

Honest Communication Builds Trust

The manufacturing plant expansion taught us that recommending solutions beyond the initial scope (like remarking old sections) builds long-term relationships. Clients value contractors who tell them what they need to hear, not just what they want to hear.

5. CONTACT SECTION

Discuss Your Industrial Project

Line Marking Australia has been completing industrial line marking projects for warehouses, manufacturing facilities, cold storage operations, food processing plants, and logistics centers since 2009. We understand operational constraints, compliance requirements, and specialized material specifications.

Director: Niel Bennet Phone: 0417 460 236 Email: info@linemarkingaustralia.com.au Address: 240 Plenty Road, Bundoora VIC 3083

Upload your facility plans, photos, and project requirements for a detailed proposal addressing your specific challenges and timeline constraints.

We provide warehouse line marking, factory line marking, and specialized industrial floor marking across all Australian states.