Industrial Warehouse Line Marking WHS Compliance Guide

A SafeWork inspector visited a distribution centre in Dandenong South last year. The warehouse had pedestrian and forklift traffic sharing the same aisles with no floor markings. The inspector issued an improvement notice with 14 days to comply. Failure to comply could have meant fines exceeding $500,000.

Warehouse line marking isn't optional decoration. It's a legal requirement under Work Health and Safety regulations. Understanding compliance requirements protects your workers and your business.

WHS Legal Requirements

The Work Health and Safety Act requires PCBUs (Person Conducting a Business or Undertaking) to eliminate or minimise risks to health and safety so far as is reasonably practicable. Floor marking is a recognised control measure for pedestrian/vehicle interaction risks.

Relevant Standards:

AS 1319: Safety signs for the occupational environment
AS 4024.1: Safety of machinery (includes floor marking guidance)
Managing the Risks of Plant Code of Practice
Forklifts and Other Powered Industrial Trucks Code of Practice

Penalty Framework:

Category 1 offence (reckless conduct): Up to $3 million (body corporate)
Category 2 offence (failure exposing to risk): Up to $1.5 million
Category 3 offence (breach of duty): Up to $500,000

Pedestrian Walkway Requirements

Pedestrian walkways must be clearly marked in any area where forklifts or other powered industrial trucks operate. This is non-negotiable under WHS requirements.

Walkway Specifications:

Minimum width: 1000mm for single-direction, 1800mm for two-way traffic
Line width: 100mm minimum recommended
Colour: Yellow with black borders, or contrasting to floor colour
Intersections: Clear marking showing pedestrian right-of-way
PEDESTRIAN ONLY text at entry points

Forklift Operating Zones

Forklift zones should be clearly delineated with markings that indicate where powered equipment operates and pedestrian access is restricted.

Zone Marking Elements:

FORKLIFT OPERATING AREA text and symbols
NO PEDESTRIAN ACCESS symbols at zone entries
Aisle direction markings for traffic flow
Stop lines at intersections and blind corners
Speed limit markings (typically 10km/h inside warehouse)

Hazard Identification Marking

AS 1319 specifies colour coding for safety signs and floor markings. Using consistent colours helps workers instantly recognise hazard types.

Standard Colour Coding:

Yellow: Caution, pedestrian routes, general awareness
Red: Fire equipment locations, emergency stops, prohibition
Green: Safety equipment, first aid, emergency exits
Blue: Mandatory actions, PPE requirements
Black/Yellow stripes: Physical hazards, trip hazards, low clearance

Storage and Exclusion Zones

Floor marking defines where goods can be stored and areas that must remain clear for safety and operational reasons.

Common Zone Types:

Pallet storage zones (white outlines for pallet positions)
Staging areas for inbound/outbound goods
Fire equipment access (1000mm clear zone around extinguishers)
Electrical panel clearance (minimum 1000mm)
Emergency exit paths (must remain clear at all times)
Dangerous goods storage areas

Material Selection for Warehouses

Warehouse floors take extreme punishment. Standard paint fails within months under forklift traffic. Material selection is critical for compliance and cost-effectiveness.

Recommended Materials:

Two-Pack Epoxy:

Best for sealed concrete floors in climate-controlled warehouses. Excellent adhesion, chemical resistance, and abrasion resistance. Typical lifespan 3-5 years under heavy forklift traffic.

Thermoplastic:

Ideal for outdoor loading areas and warehouses with temperature fluctuations. Bonds mechanically with concrete, withstands heavy traffic. Typical lifespan 4-7 years.

NOT Recommended:

Standard waterborne paint. Hard rubber forklift tyres destroy waterborne paint within weeks in high-traffic areas. The initial cost savings are negated by constant repainting.

Maintenance and Inspection

WHS requires ongoing maintenance of safety controls. Faded or damaged floor markings must be repaired promptly to maintain compliance.

Inspection Schedule:

Weekly visual inspection of high-traffic areas
Monthly comprehensive inspection of all safety markings
Document condition in safety inspection register
Schedule repairs for any degraded markings
Include floor marking in annual WHS audit

Request a warehouse WHS compliance assessment

Frequently Asked Questions

Is warehouse floor marking legally required?

Yes, where forklifts and pedestrians share workspace. The WHS Act requires elimination or minimisation of risks. Floor marking is a recognised control measure and its absence can constitute a breach of duty.

How wide should forklift aisles be marked?

Aisle width depends on forklift type and load size. General guidance is forklift width plus load width plus 600mm clearance each side. For counterbalance forklifts with standard pallets, this typically means 3.5-4.0m aisle width.

Can we use tape instead of paint?

Floor marking tape is acceptable for temporary applications but fails quickly under forklift traffic. Paint or thermoplastic provides better durability and long-term compliance. Tape edges lift and create trip hazards.

Warehouse Line Marking WHS Compliance Guide | Safety