Industrial Floor Marking with TESA & HPX: How to Build a Safe and Readable Visual System in Your Plant

In modern production plants and warehouses, more and more decisions are made literally “at floor level”. Floor lines, marked buffer zones, step edges, high-contrast posts or additional markings on cables tell operators where they may walk, where materials may be stored and which areas are associated with increased risk. If this system of signals is inconsistent, partially worn off or each department has implemented it “their own way”, it impacts not only health and safety, but also overall process flow.

This guide shows how to make smart use of TESA tapes for marking and safety: the floor marking tape TESA 60760, warning tape TESA Signal Universal 58133 / 58134, anti-slip tape TESA 60951, fabric gaffer tape TESA 4671, as well as specialist solutions such as TESA 4169, TESA 4863, TESA 4590, TESA 4695 and TESA 73210 ACXplus. Using these products as examples, we build a coherent marking system for a shop floor, warehouse or logistics centre.

All products discussed are available from Melkib, e.g. in the categories: marking tapes and anti-slip tapes.

Why invest in a TESA floor marking system at all?

Marking and warning tapes are much more than just “colourful stripes on the floor”. A well-designed visual marking system:

improves safety – it guides pedestrians away from machine operating areas and forklift traffic, and highlights particularly hazardous zones,
organises the workspace – it clearly shows where the buffer zone is, where the workstation is, and where the transport aisle runs,
speeds up the work – clear routes and zones reduce search time, errors and traffic conflicts,
supports safety, 5S and Lean audits – at a glance you can see whether the layout of the shop floor is consistent with the agreed standard,
reduces changeover costs – tapes are easier to relocate or replace than repainting the entire floor.

Self-adhesive TESA tapes can be used not only on floors, but also on walls, columns, handrails, door frames, barriers and equipment, and even directly on cable bundles. As a result, the entire work environment becomes a “readable map” for employees and visitors.

Tapes instead of paint – when is TESA the better choice?

Traditional paint markings make sense where the layout of the plant is practically fixed and processes are stable for years. In reality, however, most plants are “alive” – new machines are added, forklift routes change and outbound volumes grow.

TESA floor marking tapes offer several advantages in such an environment:

shorter downtime – surface preparation and tape application usually take less time than grinding, painting and waiting for paint to dry,
cleaner work – without dust and strong paint odours, which is important for example in food or pharmaceutical plants,
easy modification – lines can be moved, extended or partially removed when the layout or material flow changes,
consistent appearance – the entire shop floor can use one family of tapes with repeatable performance and colour coding.

This is why more and more companies treat TESA marking tapes as a tool not only for health and safety, but also for Lean and 5S – helping maintain order, clear zoning and visual workplace standards.

A logical colour system – the foundation of effective marking

To make markings easy to understand, tapes alone are not enough. You need a simple, documented colour code. In production and warehouse environments, the following scheme is very common:

yellow/black warning tapes – highlight high-risk areas (machine operating zones, rack corners, areas with limited visibility),
red/white tapes – mark “must remain clear” zones (e.g. access to fire hydrants, electrical switchboards, emergency stop devices),
yellow and white tapes – used to mark general transport routes and pallet / tote buffer areas,
green tape – highlights escape routes and safe zones, together with relevant signs and pictograms,
blue tape – can indicate areas where personal protective equipment is mandatory (e.g. hearing protection zones).

In the Melkib range you will find, among others, TESA 60760 in Neon Green, whose high-intensity colour makes it ideal for marking escape routes and key safety points – especially in areas with sub-optimal lighting.

This colour scheme should be documented in your HSE and 5S procedures, covered in training and applied consistently whenever markings are modified. That way, a new line on the floor is “self-explanatory” to employees from day one.

How to design a TESA tape-based marking system – step by step

1. Risk and flow mapping

First, you need an up-to-date “picture” of the shop floor. Walk the facility with a layout drawing and mark:

machine and equipment operating zones with moving parts,
forklift and other vehicle routes,
pedestrian routes and the points where pedestrian and vehicle traffic intersect,
access to fire hydrants, electrical switchboards, first aid points and emergency exits,
locations where incidents or “near misses” occur most frequently.

On this basis, define where you need continuous lines, where buffer zones, and where strong warning and anti-slip accents.

2. Selecting TESA and HPX tape types for each task

In practice, a single site will benefit from having several groups of products:

marking and warning tapes TESA 60760, TESA 4169 and TESA Signal Universal (58133 / 58134) – for marking routes, zones, hazard areas and structural edges,
anti-slip tape TESA 60951 and specialist solutions such as TESA 4863 “Printer’s Friend” or HPX Safety Grip – for protecting pedestrian areas as well as machine elements,
fabric gaffer tape TESA 4671 and HPX FO5025 gaffers – for temporary but secure fixing of cables and signs, especially where a matt, non-reflective surface is required,
fluorescent TESA tapes – to improve visibility wherever lighting is an issue (stairs, escape routes, low beams),
filament tape TESA 4590 – for reinforcement and “armouring” of edges particularly exposed to impact,
barrier tape TESA 4695 – for quick, temporary segregation of breakdown areas or spills,
TESA insulating tapes in small rolls – for identifying cable ends and small electrical jobs in line with colour-coding standards.

When choosing a specific tape, pay attention to whether the manufacturer classifies it as a temporary, semi-permanent or permanent solution and which substrates it is recommended for.

3. Surface preparation and application

Regardless of tape type, the basic rules are similar:

remove old tapes and paint residues that might compromise adhesion,
thoroughly vacuum and degrease the surface,
ensure the floor is dry and in reasonable technical condition,
during application, use chalk lines or lasers to keep lines straight,
press the tape firmly along its entire length, avoiding air bubbles – especially at bends and terminations.

After application, allow some time for the adhesive to build up before you reopen the area to heavy forklift traffic.

TESA 60760, TESA 4169 and TESA Signal Universal – the backbone of the system

TESA 60760 is a soft PVC floor marking tape with a modified rubber-based adhesive. It is hand-tearable, abrasion-resistant and available in several colours – from yellow and red to yellow/black or red/white. It is suitable for temporary or medium-term floor marking in production and warehouse environments.

TESA 4169 is the “premium version” for areas where forklift traffic is most intensive. It offers significantly higher abrasion and impact resistance than standard PVC tapes. It should be used in main traffic aisles, at loading docks and in zones where handling operations are virtually continuous.

TESA Signal Universal 58133 / 58134 are warning tapes on a PP backing with a water-based acrylic adhesive, designed for permanent marking of obstacles and hazard areas. Standard yellow/black and red/white variants comply with European safety colour guidelines and are UV-resistant, making them suitable also for sun-exposed areas.

Typical application scheme:

TESA 60760 – floor lines, traffic routes, buffer areas, temporary marking of work zones,
TESA 4169 – main forklift aisles, intersections, high-traffic zones where maximum abrasion resistance is required,
TESA Signal Universal (58133 / 58134) – columns, barriers, ramp edges, fixed obstacles, fence sections and other infrastructure elements that must be clearly highlighted.

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TESA 60951 and specialist solutions – anti-slip safety on steps and in the process

There are locations where visual information alone is not enough – you have to physically improve grip. This is where anti-slip tapes come into play, in particular TESA 60951 in yellow/black.

This tape uses a PVC backing coated with a mineral grit and a high-performance acrylic adhesive. It is designed to deliver a long-lasting anti-slip effect and high visibility, even in more challenging lighting conditions.

Typical applications for TESA 60951:

step and stair edges – in production areas, warehouses, mezzanines and walkways,
loading ramps and work platforms where water, mud or process contamination frequently occur,
wash areas and zones with elevated humidity, where slip risk is highest.

In more representative areas – e.g. stairs in offices, reception zones or showrooms – you can use semi-transparent HPX Safety Grip tapes, which provide an anti-slip effect without obscuring decorative substrates (stone, glass, wood).

Anti-slip for production processes – TESA 4863 “Printer’s Friend”

Anti-slip is not only about pedestrian safety. In printing, packaging and many other production processes, it is crucial that the material does not slip on rollers and that adhesive residues do not build up on them.

TESA 4863 PV3 “Printer’s Friend” is a specialist tape with a silicone surface and fabric backing, used to wrap rollers. It prevents materials from slipping, facilitates transport and reduces adhesive build-up. It is worth considering when you design “anti-slip” measures not only from the perspective of walkways, but also production processes.

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TESA 4671 and HPX gaffer tapes – quickly bringing cables and temporary installs under control

There is another type of “risk zone” in plants and warehouses: loose cables, leads and temporary installations. Anyone who has ever tripped over a cable pulled “just for a moment” across a passage knows this problem very well.

TESA 4671 is a robust fabric tape (duct / gaffer) with a rayon backing and a rubber-based adhesive. It is hand-tearable, flexible and adheres well to a wide range of substrates.

Within your safety system you can use it, for example, to:

secure cables along floors or walls, so that they no longer form tripping hazards,
temporarily secure components during trials, overhauls or line relocations,
reinforce edges of anti-slip mats, carpets and guards in areas with high foot traffic.

Thanks to its matt surface, TESA 4671 does not reflect light, making it equally suitable at inspection stations or wherever processes are documented with photos and video.

If you need a matt finish in bright, fluorescent colours, consider HPX FO5025 gaffer tapes – perfect for marking low ceilings, protruding elements, staging structures or any areas where reflections from lights would be an issue.

For small electrical jobs and colour-coding conductors, classic TESA insulating tapes in small rolls are extremely useful – they provide a simple way to mark phase, neutral and control wires.

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TESA 4695 barrier tape – temporary protection

Not all marking has to be permanent from day one. In the event of a breakdown, spill, damaged racking or maintenance work, the priority is to quickly cordon off the hazard zone.

TESA 4695 is a classic barrier tape supplied in a bag (without adhesive) that can be quickly strung between posts, on barriers or racks. It serves as the first line of protection – until permanent markings are installed on the floor or barriers.

In practice, it is worth keeping several rolls of TESA 4695 in the safety stockroom or with the shift supervisor, so that anyone can rapidly cordon off a hazardous area if needed.

Fluorescent TESA tapes – visibility where lighting is not enough

Not all areas are perfectly lit, and some traffic routes must remain readable even at minimal light levels. In such places, fluorescent TESA tapes perform very well – they stand out strongly against the background, and selected variants will also glow after prior exposure to light.

Typical applications for fluorescent TESA tapes:

marking step and platform edges,
highlighting escape routes as a complement to conventional signs,
clearly marking low beams, pipes and protruding structural elements that can be hit with a head or load.

In the Melkib range you will find, among others, TESA 60760 in Neon Green, which is perfectly suited to this role.

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Mounting signs without drilling – TESA 73210 ACXplus

A visual management system is not only about floor lines. Equally important are signs, work instructions, pictograms and labels on walls, machines and columns. In many plants these are still mounted with plugs and screws – which means drilling into walls, machine guards or rack structures.

For such applications, transparent acrylic tape TESA 73210 ACXplus is an excellent choice. It allows non-invasive mounting of information boards, document pockets, work instruction frames or escape route signs, without the risk of damaging the substrate. Unlike conventional “foam” mounting tapes, the ACXplus acrylic core delivers very high bond strength and resistance to temperature cycling.

If you are planning to implement a full 5S system, it is worth defining TESA 73210 ACXplus upfront as your standard for mounting all signs and visual aids.

TESA 4590 filament tape – reinforcement and edge “armour”

In locations most exposed to impact – e.g. rack corners, workbench edges or when securing heavy loads – a standard PVC tape may simply be too weak.

TESA 4590 is a glass-fibre reinforced filament tape used, for example, for bundling and securing loads. Within a safety marking system, it can be used as an “armour layer” on edges that are frequently struck by forklifts or loads. Thanks to its reinforcement, it tears more slowly and maintains visible warning or colour markings for longer.

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Quick reference: selected TESA tapes for safety and marking

To make product selection easier, you can use a comparison chart for TESA 60760, TESA Signal Universal, TESA 60951 and TESA 4671 in typical safety applications.

Most common mistakes when using marking tapes

Even the best TESA tapes will not deliver safety improvements if the system is designed and maintained on a “hit-or-miss” basis. In practice, the most frequent issues are:

too many colours and tape types – each department orders something different, so no one is really sure what a given colour means,
lines laid without a clear logic – pedestrian routes end in dead zones, and forklift routes intersect in critical locations,
no dedicated buffer zones – pallets and totes end up in walkways because they have no clearly marked area on the floor,
incorrect tape selection – carton sealing tape instead of gaffer tape for cables, standard marking tape instead of anti-slip on slippery steps, PVC tape instead of TESA 4169 in high-traffic areas,
lack of regular inspections – worn-off lines, lifted edges and no action until another serious incident occurs.

Summary: one system, dedicated TESA and HPX tapes

Effective plant marking is not a single roll of tape, but a coherent system in which every colour and every product type has a defined role. TESA 60760 and TESA 4169 define zones and traffic routes, TESA Signal Universal highlights obstacles and hazard areas, TESA 60951 and HPX Safety Grip protect steps and ramps, TESA 4863 ensures “anti-slip” behaviour within production processes, TESA 4671 and HPX FO5025 bring cables and temporary installations under control, fluorescent TESA tapes ensure visibility in challenging lighting conditions, and TESA 73210 ACXplus enables non-invasive mounting of boards and signage.

If you want to bring order to the marking in your plant or warehouse and you are not sure where to start and which tapes to choose, get in touch with us. Based on your operating conditions, floor type and traffic intensity, we will help you design a system that improves safety, simplifies audits and speeds up day-to-day operations.

See TESA and HPX marking, warning, anti-slip, gaffer and fluorescent tapes in the Melkib store: go to category

Frequently asked questions about marking, warning and anti-slip tapes

Which TESA tape should I choose to mark forklift routes and pedestrian walkways?

For marking traffic routes and buffer zones, floor marking tapes such as TESA 60760 in the appropriate colour (yellow, white or sometimes yellow/black) are most commonly used. Pedestrian routes can be highlighted in a different colour than vehicle routes, but always within a single, consistent colour system described in your HSE and 5S procedures.

What is the difference between TESA 60760 and TESA Signal Universal 58133 / 58134?

TESA 60760 is a typical floor marking tape – it is mainly used to mark lines, zones and buffer areas on the floor. TESA Signal Universal 58133 / 58134 are warning tapes on a PP backing, intended more for permanent marking of obstacles, columns, barriers, ramp edges and other infrastructure elements that must be clearly highlighted.

Which tapes should I use where there is a slip hazard?

For steps, ramps, platforms and slippery zones, anti-slip tapes such as TESA 60951 work best. They combine a warning function (contrasting colour – e.g. yellow/black) with a real increase in grip. In representative areas or wherever appearance matters, you can consider semi-transparent anti-slip tapes from HPX.

What is fabric gaffer tape TESA 4671 used for?

TESA 4671 is a fabric gaffer tape – ideal wherever you need to quickly and safely “tame” cables, temporary installations or secure components during trials or line relocations. Its matt finish prevents light reflections, which makes it suitable wherever inspections, photography or video recording take place on the shop floor.

Do fluorescent and neon tapes really increase safety?

Yes – both fluorescent and neon tapes significantly improve the visibility of critical locations: step edges, low beams, pipes, structural elements or escape route segments.

Fluorescent tape contains pigments that respond very strongly to light (especially UV), making it highly visible in low-light conditions. Selected variants, once “charged” with light, can remain visible even in partial darkness.

Neon tape is primarily an extremely bright, “in-your-face” colour that is highly visible under normal lighting (daylight and artificial), but does not glow in the dark by itself. It is ideal where maximum contrast and a strong warning signal are required in well-lit halls.

In practice, fluorescent tapes are better suited for escape routes and areas with poor lighting, while neon tapes are the right choice wherever you want to strongly highlight elements in a brightly lit work environment.

How often should tape-based markings be inspected?

As a minimum, markings should be checked during routine HSE walk-throughs and the entire system should be reviewed at a defined frequency (e.g. quarterly or half-yearly – depending on traffic intensity). Worn, lifted or damaged tapes should be replaced without delay, especially in high-risk areas.

Can TESA tapes be used in food and pharmaceutical plants?

In many cases, yes – provided they are used in line with the manufacturer’s recommendations and the substrate is properly prepared and kept clean. The key is to avoid situations where pieces of tape could detach and enter the product. In high-hygiene environments, tape selection and application methods should always be agreed with the HSE and quality departments.

Author: Maciej Klus – Product Manager for tapes, visual marking systems and bonding technologies at Melkib.

On a daily basis he supports HSE, Maintenance and Logistics departments in selecting tapes for marking production areas, warehouses and production lines.