Epoxy Floor Coating SWMS

Epoxy floor coating covers the preparation and application of epoxy and resin floor coatings — preparing the substrate and applying the two-pack epoxy or polyurethane coating to concrete and other floors in commercial, industrial and residential settings. The defining hazards are chemical: the epoxy resins and amine hardeners are skin and respiratory sensitisers, some polyurethane systems contain isocyanates that cause occupational asthma, the substrate preparation can release respirable crystalline silica, and the solvents and products are flammable with hazardous vapour. This document is written on the basis that epoxy floor coating is carried out by competent applicators with the chemical-sensitiser, isocyanate, silica and ventilation controls in place.

Epoxy floor coating is carried out in connection with the hazardous chemicals Code of Practice, with the epoxy resins, hardeners and any isocyanates managed as sensitisers to their safety data sheets, the substrate preparation silica controlled at the source, and ventilation provided for the vapour. The chemical sensitisers, the isocyanates, the silica from preparation, and the vapour and flammability are the defining hazards. This document coordinates the chemical-sensitiser, isocyanate, silica and ventilation controls so the epoxy floor coating is applied safely.

Hazards identified

9 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Administrative: where the coating or adhesive is a two-pack epoxy or polyurethane system, manage the epoxy resins and amine hardeners as skin and respiratory sensitisers and any isocyanates as respiratory sensitisers to their safety data sheets, with skin protection, ventilation and respiratory protection, because isocyanates and sensitisers can cause occupational asthma and dermatitis.
2. 2Administrative: manage the epoxy resins, amine hardeners and coating chemicals to their safety data sheets, with skin protection, avoiding skin and eye contact, because the resins and hardeners are sensitisers that cause dermatitis and respiratory sensitisation.
3. 3Engineering: control respirable crystalline silica from grinding, cutting or surface preparation of concrete, terrazzo or screeds at the source — on-tool water suppression or H-class dust extraction — never dry-grinding uncontrolled, with respiratory protection as required, recognising the workplace exposure standard for silica reduces on 1 December 2026.
4. 4Engineering: provide ventilation where using solvent-based adhesives, primers, finishes or coatings, and control the flammable vapour and ignition sources, managing the chemicals to their safety data sheets.
5. 5Engineering: provide ventilation where applying the coating, particularly in enclosed or poorly ventilated areas, with respiratory protection for the vapour and any isocyanates.
6. 6Administrative: manage slips on the freshly coated or wet floor with barriers and signage, and manage the manual handling and kneeling postures.
7. 7Engineering: use the sanders, grinders, mixers and tools safely to the plant requirements, with guarding and the manufacturer's instructions, and have any electrical work and connection by a licensed electrician.
8. 8Administrative: all workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) where the work is construction work, with the flooring, asbestos-awareness and any other competencies required for the work.
9. 9Administrative: conduct a pre-start toolbox talk covering the day's work, identified hazards, required PPE and emergency procedures, and record attendance in the consultation section.
10. 10Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
11. 11PPE: eye protection to AS/NZS 1337.1, hearing protection where required, gloves appropriate to the task, knee protection for kneeling work, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
12. 12Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.
13. 13Administrative: ensure the work is carried out by competent flooring installers, with any electrical work by a licensed electrician and any asbestos removal by a licensed asbestos removalist, under the applicable requirements.

Applicable Codes of Practice

Worked example

A flooring applicator is engaged to apply a two-pack epoxy coating to an industrial concrete floor. Because the coating is a two-pack system, the epoxy resins and amine hardeners are managed as skin and respiratory sensitisers, and any isocyanates in a polyurethane topcoat as respiratory sensitisers, to their safety data sheets, with skin protection, ventilation and respiratory protection, because isocyanates and sensitisers can cause occupational asthma and dermatitis. Skin and eye contact with the coating chemicals is avoided. Respirable crystalline silica from grinding and preparing the concrete substrate is controlled at the source with on-tool water suppression or H-class extraction, never dry-grinding uncontrolled, with respiratory protection, recognising the silica exposure standard reduces on 1 December 2026. Ventilation is provided where applying the coating, particularly in enclosed areas, and the flammable solvents and vapour controlled. Slips on the freshly coated floor are managed with barriers and signage, and the manual handling and kneeling postures managed. The substrate preparation plant is used safely. The coating is applied, and the records retained.

Related legislation

• Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
• Model Work Health and Safety Regulations — the asbestos provisions and licensing, the hazardous chemicals and silica provisions, and the Section 291 high risk construction work and SWMS duties where applicable, as enacted in each jurisdiction.
• The asbestos Codes of Practice (managing and controlling asbestos, and safely removing asbestos), the hazardous chemicals and silica requirements, and the respiratory protection standards AS/NZS 1715 and AS/NZS 1716, are called up by the relevant safety legislation, together with the construction and product requirements.
• Asbestos removal is licensed under each state and territory's asbestos licensing scheme, with friable asbestos and asbestos made friable by the removal method requiring a Class A asbestos removal licence holder; electrical work is carried out by a licensed electrician.
• Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the asbestos, hazardous chemicals and high risk construction work provisions applying in place of the model instruments.

Frequently asked questions