Many warehouse and site managers start with painted lines to mark out pedestrian walkways and vehicle zones, and for good reason. It’s quick, cost-effective and often seen as a “good enough” solution in the early stages of a facility’s development.
But as site activity increases and risks rise, a question emerges: "When is paint no longer enough?"
In this article, we’ll help you understand the warning signs, risk triggers, and safety expectations that indicate it’s time to move from floor markings to physical pedestrian segregation systems.
Painted walkways are widely used to:
Visually guide pedestrian flow
Indicate safe crossing points
Separate pedestrian and forklift zones
They’re a low-cost solution that can be applied quickly, which makes them a popular first choice.
But paint comes with limits:
It doesn’t prevent forklifts from entering pedestrian zones
It wears away under heavy traffic and cleaning
It offers no physical protection in the event of impact
Eventually, what started as a helpful guide may become a false sense of security.
Not sure if your site still suits painted walkways? Ask yourself:
Have you had a near miss or accident involving a pedestrian and vehicle?
→ Visual-only segregation won’t be enough in high-risk zones
Are your painted lines faded or ignored by drivers?
→ If visibility or compliance is a challenge, paint isn’t doing its job
Has foot or vehicle traffic increased significantly?
→ Higher volume means higher risk — and paint won’t stop an impact
Are your pedestrian routes close to high-speed or heavy MHE?
→ The closer the proximity, the higher the need for a physical barrier
Have you changed your layout or added new processes?
→ If you’ve reconfigured your site but left the paint, it’s time to reassess
Upgrading to a physical barrier system (such as polymer pedestrian segregation barriers) brings key advantages:
Physically protects people from FLTs and material handling vehicles
Absorbs and deflects impact without damaging vehicles or flooring
Maintains clear, high-visibility routes for staff and visitors
Complies with modern safety best practices, including PAS 13
While paint may still be suitable for low-traffic areas, physical barriers are essential in:
Cross-aisle intersections
Loading and unloading zones
Entry/exit points to walkways
Confined spaces where FLTs and pedestrians interact
Areas where line of sight is reduced (blind corners, racking ends, etc.)
If your site includes any of the above, painted lines alone will not meet modern safety expectations.
We understand the hesitation: physical barriers involve a higher upfront cost than paint. But consider the true cost of doing nothing:
Downtime after an incident
Investigations and enforcement action
Injury claims and insurance impact
Reduced morale and trust from staff
Most customers we work with find that the long-term savings in accident prevention, maintenance, and compliance outweigh the initial install costs. In fact, many start small with a single area as a lighthouse project, and scale from there.
Curious about costs? Explore our pricing options here.
If you’ve already invested in paint and still find yourself asking if it’s enough, it probably isn’t.
At Clarity, we help warehouse, logistics and manufacturing sites make the shift from visual to physical safety with flexible, modular solutions that suit any layout.
Still unsure? We’re happy to advise with no pressure or obligation.