Epoxy Walkways & Forklift Routes
In this project we installed long-life epoxy line markings inside a busy warehouse while production continued. We mechanically prepared the concrete—surface grinding for the main field and shot-blasting to create crisp, straight edges—then hand-applied a hard-wearing internal epoxy system to form walkways, keep-clear zones and forklift operating routes.
The client needed line markings designed to last 5–10 years without frequent touch-ups—and they couldn’t close the site. Our phased plan kept operations flowing and handed back bright, durable routes that make the warehouse safer and easier to navigate.
Project Snapshot & Outcome
Location: UK warehouse (polished concrete slab). Scope: Mechanical prep (grinding + edge shot-blast), priming where required, hand-applied epoxy line markings for pedestrian walkways, forklift aisles, keep-clear hatchings and door thresholds. Programme: Live-site, phased cordons to avoid downtime.
Outcome: High-contrast routes that withstand forklift traffic, pallet jacks and daily cleaning—reducing near-misses and making flows predictable for 5–10 years with routine care.
The Health & Safety Manager’s perspective:
Your brief is simple but demanding: upgrade safety and wayfinding without stopping production. By phasing works into compact cordons and using a mechanically keyed epoxy system, we created walkways and forklift lanes that cure hard, last longer and stand up to scrubbing—so you protect people and throughput at the same time.
We coordinated shifts, set clear diversions and reopened each zone as soon as practical. Your team stayed productive while the site visibly became safer under their feet.
Challenges & Solutions
1) Keep the warehouse open
Production couldn’t pause, but we needed safe access to working areas.
Solution: Phased cordoned zones with cones and signage. We sequenced around break times and changeovers; completed smaller sections first for early wins; and reopened areas rapidly as coatings reached handling strength.
Guidance: HSE: Workplace transport safety
2) Long service life (5–10 years)
Paint must tolerate forklifts, turning, pallet drag and scrubber-dryer regimes.
Solution: Internal epoxy line marking system with mechanical profile from diamond grinding and edge shot-blasting. Where needed, we used a compatible primer to lock onto dense concrete and improve adhesion in high-stress lanes.
Related reading: Grinding & shot-blasting prep
3) Straight, crisp edges
Walkways must look professional and stay legible after cleaning.
Solution: Shot-blaster for edges to create straight, consistent borders; masking for legends; and controlled hand application for solid, opaque colour and tidy lines.
4) Clear people–vehicle separation
The client needed unmistakable routes for pedestrians and forklifts.
Solution: High-visibility pedestrian walkways, lane arrows and forklift operational areas; keep-clear hatchings at doors and pinch points to preserve sightlines and turning space.
Best practice: HSG136: Workplace transport safety (PDF)
Technical Specification (What We Used & Why)
Mechanical Surface Preparation: Diamond surface grinding for the main slab to remove laitance/contamination and generate profile; shot-blasting at line edges for a straight, high-energy key that improves edge durability and appearance.
- Dust-controlled equipment and targeted edge work to minimise disruption.
- Localised crack/spall repairs where identified before coating.
Internal Epoxy Line Marking System (hand-applied): Two-component epoxy with high solids for opacity and wear resistance on internal concrete. Selected for long service life under forklift traffic and compatibility with routine scrubber-dryer cleaning.
- Typical build: 1–2 coat system to specified film thickness; primer used on dense/contaminated areas as needed.
- Cure: workable reopen windows planned per temperature/humidity to restore access quickly.
- Colour: high-contrast walkway green/yellow/white (as specified) with durable borders.
- Options: anti-slip aggregate at door thresholds and ramps; polyurethane glaze for extra cleanability if specified.
Related services:
Warehouse Line Marking ·
Walkways & Pedestrian Routes ·
How to deal with paint spills.
Our Live-Site Process
- Survey & plan: Map pedestrian desire lines, forklift aisles, doors and blind spots; agree colours and legend schedule.
- Phasing & comms: Create small cordons; brief shift leads; align to breaks/changeovers; set temporary routes.
- Prep: Dust-control, diamond grind field areas; shot-blast edges; repair local defects; prime where required.
- Apply epoxy: Mask edges/legends; hand-apply epoxy coats to film thickness; anti-slip where specified.
- Reopen & move: Verify cure/handling strength; remove masking at tack-set for crisp edges; advance to next cordon.
- Sign-off & aftercare: Client walk-through; cleaning guidance; optional refresh schedule to maintain gloss/contrast.
Benefits You Keep Long-Term
Robust epoxy lines resist wear from forklifts and cleaning, staying legible for years. Clear walkways and lanes reduce hesitation and near-misses, while phased working keeps the warehouse productive throughout the install.
Net result: a safer, more efficient floor layout with fewer call-backs and lower lifetime cost.
Next Steps
Need durable internal line marking without shutting the warehouse? We’ll survey, plan the cordons and deliver a mechanically keyed epoxy system designed to last.
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Useful external resources:
HSE: Workplace transport safety ·
HSG136: Workplace transport safety (PDF).
