Maintaining Your Safety Signs: Inspection and Replacement Guide

Installation Overview

How to maintain, clean, and determine when to replace your safety signs to ensure continued compliance. Proper installation ensures signs remain secure, visible, and compliant with UK regulations throughout their lifespan.

Pre-Installation Planning

1. Site Survey and Risk Assessment

Before purchasing or installing any signs:

Identify Hazards:

• Conduct thorough walkthrough
• Review existing risk assessments
• Consult with supervisors and employees
• Note areas of previous incidents
• Consider future workplace changes

Map Locations:

• Plot sign positions on floor plan
• Note viewing distances
• Identify potential obstructions
• Consider lighting conditions
• Plan for emergency evacuation routes

2. Regulatory Compliance Check

Ensure installations meet:

• BS EN ISO 7010:2020 (current standard)
• Health and Safety (Safety Signs and Signals) Regulations 1996
• Regulatory Reform (Fire Safety Order 2005)
• Industry-specific requirements (e.g., CDM 2015 for construction)

3. Material and Fixing Selection

Match materials to environment:

• Indoor smooth surfaces → Self-adhesive vinyl
• Indoor permanent → Rigid plastic with screws
• Outdoor → Aluminium or weatherproof plastic
• High vandalism → Polycarbonate
• Emergency routes → Photoluminescent

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Height and Positioning Requirements

Standard Mounting Heights

General Safety Signs:

• Optimal height: 1.5m to 2.0m (eye level)
• Measured from floor to sign center
• Adjust for average workforce height
• Consider wheelchair user sightlines

Fire Exit Signs:

• Above door frames: 300mm minimum above door
• Low-level: 300mm above floor (smoke visibility)
• Both positions recommended for comprehensive safety

Warning Signs at Hazard Points:

• Immediately before hazard: 2-5m approach distance
• At point of hazard: Eye level where safe
• Entry to hazardous zones: Door frame level

Mandatory PPE Signs:

• Zone entry points: Before entry to area
• 1.8m height: Clear visibility
• Multiple positions: For large areas

Visibility Requirements

Signs must be visible from:

• All normal approach angles
• Expected working positions
• Adequate distance for action/decision time
• Without obstruction when doors/equipment operate

Minimum Viewing Distances:

Sign Size (mm) | Max Viewing Distance
150 x 150      | 10 metres
200 x 200      | 20 metres
300 x 300      | 30 metres
400 x 400      | 50 metres
600 x 600      | 75 metres

Lighting Considerations

Adequate Illumination:

• Minimum 50 lux at sign face
• Consider natural light variations
• Supplement with artificial lighting if needed
• Or use photoluminescent signs

Photoluminescent Requirements:

• Mandatory for emergency routes
• Must receive adequate light charging
• Minimum 54 lux for 15 minutes
• Test regularly for glow performance

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Installation Methods

Method 1: Screw Fixing (Rigid Signs)

Best for: Permanent installations, rigid plastic, aluminium, polycarbonate

Tools Required:

• Spirit level
• Tape measure
• Pencil
• Drill with appropriate bits
• Screwdriver or drill driver
• Wall plugs (for masonry)
• Appropriate screws

Step-by-Step Process:

1. Position Sign:

   • Hold sign at desired location
   • Use spirit level to ensure horizontal
   • Mark center point with pencil

2. Mark Fixing Holes:

   • Mark all fixing hole positions
   • Typically 4 corners for stability
   • Large signs may need additional center fixings

3. Drill Pilot Holes:

   • Select appropriate drill bit
   • For masonry: Use masonry bit, insert wall plugs
   • For wood/plaster: Smaller pilot hole prevents splitting
   • For metal: Use metal drill bit

4. Fix Sign:

   • Align sign with pilot holes
   • Insert screws through sign into holes
   • Tighten evenly, don't over-tighten
   • Check level again
   • Ensure sign sits flat against surface

Screw Selection Guide:

• Indoor/Dry: Standard steel screws
• Outdoor/Damp: Stainless steel or coated screws
• Chemical environments: Chemical-resistant fasteners
• Size: Appropriate for sign weight and material

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Method 2: Self-Adhesive Installation (Vinyl Signs)

Best for: Smooth surfaces, non-permanent installations, lightweight signs

Surface Requirements:

• Smooth (not textured or rough)
• Clean and dry
• Free from grease/dust/moisture
• Temperature above 10°C during application

Tools Required:

• Cleaning cloth
• Degreaser/alcohol wipes
• Squeegee or soft cloth
• Tape measure
• Spirit level
• Pencil (for positioning marks)

Step-by-Step Process:

1. Surface Preparation (Critical):

   • Clean thoroughly with degreaser
   • Remove all dust, grease, and contaminants
   • Dry completely
   • For painted surfaces, ensure paint fully cured (28 days)

2. Position Marking:

   • Measure and mark desired position
   • Use spirit level for alignment
   • Light pencil marks at corners

3. Application:

   • Peel back 2-3cm of backing paper
   • Align sign with position marks
   • Slowly press down from one edge
   • Gradually peel backing while smoothing sign
   • Use squeegee to prevent air bubbles
   • Work from center outward

4. Final Steps:

   • Press firmly along all edges
   • Pay special attention to corners
   • Remove any air bubbles by pushing toward edge
   • Allow 24 hours cure time before exposure

Temperature Considerations:

• Ideal application: 15-25°C
• Below 10°C: Adhesive may not bond properly
• Above 30°C: Difficult to handle, may bubble

Common Failure Causes:

• Surface not clean/dry
• Application in cold conditions
• Insufficient pressure on edges
• Premature exposure to weather

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Method 3: Cable Tie Fixing (Mesh/Fencing)

Best for: Wire mesh, chain link fencing, temporary barriers

Tools Required:

• UV-resistant cable ties
• Cable tie gun or pliers
• Wire cutters

Process:

1. Position sign on mesh/fencing
2. Thread cable tie through sign holes and mesh
3. Pull tight with cable tie gun
4. Cut excess tie length
5. Use minimum 4 cable ties per sign
6. Check regularly and replace degraded ties

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Method 4: Magnetic Fixing (Temporary)

Best for: Temporary signs on steel surfaces (e.g., vehicles, containers)

Requirements:

• Ferrous metal surface
• Clean, smooth surface
• Strong neodymium magnets for outdoor use

Process:

1. Clean metal surface
2. Attach magnetic fixings to sign
3. Position carefully (strong magnets attract suddenly)
4. Check security regularly
5. Remove during high winds if lightweight

Limitations:

• Only on ferrous metals
• Regular checking essential
• Not for permanent installations
• Can be removed by others

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Special Installation Scenarios

Fire Exit Signs

Critical Requirements:

• Must be photoluminescent or internally illuminated
• Visible from all evacuation routes
• Not obscured when doors open
• Above door: Minimum 300mm clear above door frame
• Low-level: 300mm above floor level recommended

Directional Arrows:

• Indicate correct evacuation direction
• Change of direction requires new sign
• Final exit signs point to door
• Ensure clarity (avoid ambiguous directions)

First Aid Points

Requirements:

• Green and white colour scheme
• Clear visibility from all work areas
• Located at or above first aid facilities
• Additional directional signs if needed

Hazardous Substance Areas

COSHH Requirements:

• Warning signs before entry
• Mandatory PPE signs at entry
• Emergency procedure information
• Compatible with substance hazards

Multi-Storey or Complex Buildings

Wayfinding Strategy:

• Comprehensive signage plan
• Signs at decision points
• Distance information where helpful
• Consistent design and placement
• Regular review and updates

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Quality Assurance Checks

Post-Installation Verification

Immediate Checks:

• [ ] Sign level and straight
• [ ] All fixings secure
• [ ] No damage during installation
• [ ] Correct sign for location
• [ ] Appropriate height
• [ ] Clearly visible from approach angles

Photoluminescent Sign Testing:

• Charge sign in normal lighting (15 minutes)
• Darken area or cover sign
• Verify adequate glow
• Check glow duration (should last hours)

Documentation:

• Record installation date
• Photograph installations
• Update site sign inventory
• Note any deviations from plan
• Schedule first inspection date

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Maintenance Schedule

Weekly Checks (High-Traffic Areas)

• Visual inspection for damage
• Check security of fixings
• Note any obstructions
• Report issues immediately

Monthly Checks (All Signs)

• Clean signs with mild detergent
• Check fixing security
• Test photoluminescent glow
• Remove obstructions

Quarterly Checks

• Detailed inspection of all signs
• Check against risk assessment
• Replace damaged signs
• Update sign inventory
• Review placement effectiveness

Annual Audit

• Comprehensive site review
• Match to current risk assessments
• Check for regulation updates
• Replace faded signs
• Professional photography
• Full compliance documentation

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Common Installation Mistakes

Mistake 1: Incorrect Height

Problem: Signs too high or low for optimal visibility
Solution: Follow 1.5-2.0m guideline, adjust for specific situations

Mistake 2: Obstructions Ignored

Problem: Sign hidden when doors open, equipment moved, or seasonal changes
Solution: Test all operational scenarios before final fixing

Mistake 3: Poor Surface Preparation

Problem: Self-adhesive signs fall off within days
Solution: Thorough cleaning, degreasing, and drying before application

Mistake 4: Wrong Fixing Method

Problem: Rigid signs with adhesive backing on textured walls
Solution: Match fixing method to sign material and surface type

Mistake 5: Inadequate Size

Problem: Sign too small for viewing distance
Solution: Use viewing distance chart to select appropriate size

Mistake 6: No Photoluminescent on Fire Exits

Problem: Exit signs invisible during power failure
Solution: Always use photoluminescent or emergency lit signs

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Tools and Equipment Checklist

Basic Installation Kit

Measuring and Marking:

• [ ] 5m tape measure
• [ ] Spirit level (600mm minimum)
• [ ] Pencil and marker
• [ ] Plumb line (for multi-sign alignment)

Drilling and Fixing:

• [ ] Cordless drill/driver
• [ ] Drill bit set (wood, masonry, metal)
• [ ] Screwdriver set
• [ ] Wall plugs (various sizes)
• [ ] Screws (appropriate types)

Surface Preparation:

• [ ] Degreaser/cleaning solution
• [ ] Clean cloths
• [ ] Alcohol wipes
• [ ] Squeegee

Safety Equipment:

• [ ] Safety glasses
• [ ] Dust mask (for drilling)
• [ ] Stepladder (appropriate height)
• [ ] Gloves

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Professional Installation Services

When to Use Professional Installers

Consider professional installation when:

• Large-scale projects (50+ signs)
• Height access requires specialist equipment
• Complex buildings with wayfinding systems
• Compliance audit recommendations
• No in-house capability for safe installation
• Liability concerns in public areas

What Professionals Provide

• Site survey and signage plan
• Regulatory compliance verification
• Safe working at height
• Professional installation
• Quality assurance testing
• Documentation and certification
• Maintenance schedules

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Conclusion

Proper installation of safety signs is as important as selecting the right signs in the first place. Poorly installed signs can:

• Fail to communicate effectively
• Create compliance issues
• Increase liability
• Require early replacement
• Undermine safety culture

By following this guide and maintaining regular inspection schedules, you ensure your safety signs provide maximum protection, comply with regulations, and represent a sound long-term investment.

For complex installations or professional installation services, contact our certified installation team who can ensure regulatory compliance and optimal positioning.