Product Overview

Summary: This Epoxy Flooring Application Safe Operating Procedure provides a clear, step-by-step method for preparing, mixing and applying epoxy flooring systems safely and consistently. It helps Australian businesses control hazardous chemical exposure, slip and trip risks, and site contamination while delivering a durable, high-quality finish that meets WHS and client expectations.

Epoxy flooring is widely used across Australian industrial, commercial and construction environments due to its durability, chemical resistance and ease of cleaning. However, improper preparation, mixing or application can expose workers to hazardous vapours, create long-term slip and trip hazards, and result in costly rework or system failure. This Epoxy Flooring Application SOP gives your team a practical, WHS-aligned framework for managing each stage of the process – from substrate inspection and moisture testing through to curing, decontamination and reinstatement of operations.

The procedure sets out defined roles, required competencies and mandatory PPE, along with detailed controls for handling resins, hardeners, solvents and cleaning agents. It addresses common on-site challenges such as poor ventilation, confined or partially enclosed spaces, ignition sources, dust and noise from mechanical preparation, and managing third-party access during curing. By implementing this SOP, businesses can demonstrate due diligence under Australian WHS laws, reduce the likelihood of health issues such as dermatitis and respiratory irritation, and avoid project delays caused by coating failures, non-compliant surfaces or safety incidents.

Designed for real-world use on construction sites, in warehouses, workshops, food processing plants and car parks, this SOP also standardises quality outcomes. It defines acceptance criteria for surface profile, film thickness, curing times and slip resistance, and integrates pre-start checks, environmental conditions monitoring and documentation requirements. The result is a repeatable, defensible and auditable epoxy flooring process that protects workers, maintains client trust and extends the life of your flooring systems.

Key Benefits

• Ensure safe handling and application of epoxy resins, hardeners and solvents in line with Australian WHS requirements.
• Reduce worker exposure to hazardous vapours, skin irritants and sensitising agents through clear PPE and ventilation controls.
• Standardise floor preparation and application methods to minimise coating failures, blistering, delamination and rework.
• Improve site safety by managing slip, trip, fall and access risks during application and curing stages.
• Demonstrate compliance and due diligence to regulators, principal contractors and clients with structured records and sign-offs.

Who is this for?

• Epoxy Flooring Installers
• Flooring Contractors
• Construction Site Supervisors
• Project Managers
• WHS Managers
• Facilities Managers
• Maintenance Supervisors
• Industrial Painters and Coaters
• Warehouse and Operations Managers

Hazards Addressed

• Exposure to epoxy resins, hardeners and solvents (skin contact, eye contact, inhalation)
• Respiratory irritation and sensitisation from vapours and dusts during surface preparation
• Dermatitis and allergic reactions from repeated or unprotected skin exposure
• Fire and explosion risks from flammable solvents and ignition sources
• Slip, trip and fall hazards on wet, tacky or partially cured epoxy surfaces
• Manual handling injuries from lifting and moving drums, mixing containers and grinding equipment
• Noise and vibration exposure from mechanical surface preparation tools
• Dust inhalation and eye injuries from grinding, shot blasting or scarifying concrete
• Confined or poorly ventilated workspace hazards, including oxygen depletion and fume build-up
• Chemical spills, environmental contamination and improper waste disposal

Included Sections

• 1.0 Purpose and Scope
• 2.0 References and Applicable Standards
• 3.0 Definitions and Abbreviations
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Required PPE, Tools and Equipment
• 6.0 Material Safety Data and Hazardous Chemical Management
• 7.0 Pre-Start Planning and Site Assessment
• 8.0 Substrate Inspection, Testing and Surface Preparation
• 9.0 Environmental Conditions and Ventilation Requirements
• 10.0 Mixing Procedures for Epoxy Components
• 11.0 Application Methods (Primers, Body Coats, Topcoats and Non-Slip Systems)
• 12.0 Curing, Protection of Work Area and Access Control
• 13.0 Quality Control, Inspection and Acceptance Criteria
• 14.0 Housekeeping, Spill Management and Waste Disposal
• 15.0 Hazard Identification and Risk Control Measures
• 16.0 Emergency Procedures (Exposure, Fire, Spills)
• 17.0 Training, Induction and Competency Verification
• 18.0 Documentation, Record Keeping and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) – Hazardous chemicals and risk management
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161: Occupational protective gloves
• AS 4586: Slip resistance classification of new pedestrian surface materials
• AS 1884: Floor coverings – Resilient sheet and tiles – Installation (as guidance for substrate preparation practices)
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161.1: Occupational protective gloves – Selection, use and maintenance