Product Overview

Summary: This Stencilling Techniques Safe Operating Procedure sets out safe, consistent methods for preparing surfaces, handling paints and solvents, and applying stencils in Australian workplaces. It helps organisations control chemical exposure, overspray, slips, and manual handling risks while achieving clean, professional results every time.

Stencilling is used across Australian workplaces for line marking, safety signage, branding, and product identification, often involving paints, aerosols, adhesives and cutting tools. Without a structured procedure, workers can be exposed to harmful vapours, slips from overspray, eye injuries, and repetitive strain, while businesses face inconsistent quality, rework and potential non-compliance with WHS and workplace traffic management requirements. This Stencilling Techniques SOP provides a clear, step-by-step framework to plan, prepare and carry out stencilling tasks safely and efficiently in workshops, warehouses, car parks, construction sites and production facilities.

The document guides workers through surface assessment and preparation, stencil selection and layout, safe use of paints and solvents (including aerosols), ventilation requirements, PPE selection, and controlled application techniques to minimise overspray and waste. It also addresses housekeeping, drying and curing times, barricading of wet areas, and clean-up and waste disposal in line with Australian environmental and WHS expectations. By implementing this SOP, organisations can demonstrate due diligence under WHS legislation, support consistent training for new and existing staff, and protect both workers and the public wherever stencilling activities occur.

Key Benefits

• Ensure stencilling work is carried out in line with Australian WHS duties, including safe handling of paints, aerosols and solvents.
• Reduce the risk of slips, trips, eye irritation and respiratory issues caused by overspray, vapours and poor housekeeping.
• Standardise stencilling quality across teams, improving legibility, durability and professional presentation of markings and signage.
• Streamline training and onboarding by giving workers a clear, visual step-by-step process for surface preparation and application.
• Minimise rework, material waste and downtime through correct surface preparation, drying times and barricading of work areas.

Who is this for?

• Signwriters
• Industrial Painters
• Line Marking Contractors
• Facilities and Maintenance Managers
• WHS Managers and Advisors
• Workshop Supervisors
• Construction Site Supervisors
• Traffic Management and Line Marking Supervisors
• Manufacturing Team Leaders
• Apprentice Trainers and Vocational Educators

Hazards Addressed

• Exposure to solvent and paint vapours from aerosols and liquid coatings
• Skin and eye contact with paints, thinners and cleaning agents
• Inhalation of dust from surface preparation (e.g. light sanding, cleaning)
• Slips and trips from overspray, spills and poorly controlled work areas
• Manual handling strains from handling stencil boards, paint containers and equipment
• Cuts and lacerations from cutting or trimming stencils with knives or blades
• Fire and explosion risks from flammable paints, aerosols and solvents
• Environmental contamination from incorrect disposal of paint waste and solvents
• Vehicle and pedestrian interaction risks during line-marking and outdoor stencilling

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Stencilling Tasks
• 6.0 Required PPE and Safety Equipment
• 7.0 Tools, Materials and Stencil Types
• 8.0 Pre-Start Checks and Site Preparation
• 9.0 Surface Preparation and Cleaning Procedures
• 10.0 Stencil Layout, Positioning and Fixing Methods
• 11.0 Safe Use of Paints, Aerosols and Solvents
• 12.0 Stencilling Application Techniques (Spray, Roller, Brush)
• 13.0 Ventilation, Fume Control and Environmental Considerations
• 14.0 Managing Overspray, Spills and Housekeeping
• 15.0 Drying, Curing and Barricading of Work Areas
• 16.0 Clean-Up, Waste Management and Disposal
• 17.0 Manual Handling and Storage of Stencils and Materials
• 18.0 Emergency Procedures and First Aid Considerations
• 19.0 Training, Competency and Supervision Requirements
• 20.0 Inspection, Quality Control and Documentation
• 21.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and harmonised state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory regulations
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS 1319: Safety signs for the occupational environment
• Austroads Guide to Traffic Management (for road and car park line marking contexts)