Service Station Canopy Repainting Case Study: Wyong M1 in 2 Days With No Closure
ATD recently repainted the structural columns under the fuel canopy at the Wyong Northbound service centre on the M1 Pacific Motorway. It's one of Australia's busiest service stations, on a stretch of motorway carrying approximately 45,000 vehicles a day, and it trades around the clock for cars and heavy vehicles alike. Closing the forecourt was never an option.
The results:
Approximately 45,000 vehicles a day passing the site on the M1
Completed in 2 days
No forecourt closure at any stage
18 bowsers kept operating at the same time throughout the works
The works were delivered under live site conditions. Work zones were rotated around the forecourt so the operational bowsers never dropped below 18. Each column was barricaded, prepared, primed and recoated before its area returned to service.
Our team worked under the WPCG work clearance system that applies at major fuel company sites. Every task was authorised, controlled and signed off in line with the site operator's safety requirements.
Why service station canopy columns deteriorate so quickly
Canopy columns take more punishment than almost any other painted surface on a commercial site:
Vehicle and trolley impacts chip the coating at bumper height, exposing bare steel
Fuel splash and drips soften and stain coatings not designed for chemical resistance
Hose and nozzle strikes wear through paint on columns next to dispensers
Washdowns and road grime keep the base of each column wet and dirty
Water pooling at base plates lets rust creep under the paint film, often hidden until it bubbles through
Once corrosion takes hold at the base of a column, it spreads fast. A repaint done early is a coating job. A repaint done late can become a steel repair job.
Can a service station stay open during repainting?
Yes. The key is working pump island by pump island rather than across the whole forecourt at once. A typical approach looks like this:
Plan the sequence with the site operator. Agree which islands close, in what order and for how long, so most pumps stay available at all times.
Avoid peak periods. Work around morning and evening commuter peaks and scheduled tanker deliveries. On high-volume sites, night work can reduce disruption further.
Barricade each work zone. Clearly marked barriers keep vehicles and pedestrians away from the work area and from wet coatings.
Keep traffic flowing. Signage and cones direct drivers to the open pumps so the site keeps moving.
Return each island to service promptly. Coatings are allowed to cure enough to resist handling before barriers come down, then the team moves to the next island.
The same live-site principles apply across retail and trade sites. See our guides to live retail refreshes and repainting without closing your doors.
Safety on a live fuel site
Painting on a fuel site isn't like painting a warehouse. Areas around dispensers and fill points are hazardous areas, where fuel vapour can be present.
That's why the major fuel companies control who can work on their sites. Work Place Clearance Group (WPCG) training and accreditation are required for anyone conducting work on member company fuel facilities. Lower-risk maintenance is carried out under a WPCG Work Clearance, and higher-risk work requires a WPCG Work Permit.
ATD is WPCG accredited, so our crews can work on these sites without waiting on third-party clearances. In practice, that accreditation shapes how the job is run:
Clearances and inductions. Every worker is inducted, and each task is authorised under the site's clearance or permit system before it starts, including emergency stop locations and spill response.
Ignition source control. Tools that can create sparks, such as angle grinders, need extra controls under hot work requirements, and nearby dispensers may need to be isolated. Where possible, preparation methods are chosen to avoid ignition risk altogether.
Application method. Brush and roller application is often preferred near dispensers, because it avoids static and overspray risks and keeps paint off customers' vehicles.
Spill and waste control. Paint, solvents and wash water must be contained and kept out of forecourt drains and interceptors.
Public interface. Customers are walking and driving through the site the whole time, so barricading and supervision can't lapse.
If you're comparing contractors for fuel site work, ask to see their WPCG accreditation before anything else. Our four questions to ask before hiring commercial painting contractors covers what else to check.
Preparation: where the job is won or lost
Most canopy column failures come from poor preparation, not poor paint. A proper scope includes:
Degreasing and washing to remove fuel residue, road film and grime, which stop new coatings from bonding
Removing loose and failed paint, especially around impact damage and at column bases
Treating corrosion back to sound steel, then priming immediately so rust doesn't return
Using the right primer for the substrate. Galvanised steel, painted steel and clad columns each need a compatible system.
Sealing base plate junctions so water can't sit and undermine the new coating
Choosing the right coating system for canopies and columns
Standard decorative paint won't last on a forecourt. Canopy structures need a system that resists impact, fuel splash, UV and regular cleaning. A typical specification uses:
An anti-corrosive epoxy primer on repaired and bare steel
A two-pack polyurethane topcoat for hardness, chemical resistance and long-term colour and gloss retention
Safety yellow on columns, bollards and impact zones where required
Exact brand colour matching so every site in a fuel network presents identically
For operators with multiple sites, batch-controlled colours and a standard specification keep every forecourt consistent. We covered this in our multi-site brand consistency case study. Learn more about our branded environments and protective coatings work.
Beyond the columns: completing the forecourt refresh
While the team is on site, it often makes sense to refresh the rest of the forecourt at the same time:
Canopy soffits and fascias
Bollards and wheel stops
Pump island kerbs
Forecourt line marking, directional arrows and parking bays
Painted pump numbers and site signage (see painted signage and wayfinding)
The convenience store exterior
Bundling these into one staged programme means a single mobilisation and one period of disruption instead of several.
Keeping forecourts looking sharp between repaints
Impact damage on columns is inevitable. A planned maintenance program with scheduled inspections and touch-ups catches chips before rust spreads. That extends the life of the full repaint and keeps sites looking on-brand year-round. For fuel networks, a single WPCG accredited contractor can maintain consistent standards across every location.
Service station painting FAQs
Do we have to close the service station to repaint the canopy?
No. Canopy columns and forecourt structures can be repainted in stages, with the rest of the site trading normally. At the Wyong Northbound M1 service centre, ATD completed the canopy column repaint in two days with no closure, keeping 18 bowsers operating at the same time throughout.
What is WPCG accreditation and why does it matter?
The Work Place Clearance Group (WPCG) is run by Australia's major fuel companies. Its training and accreditation are required for anyone working on their fuel facilities. Hiring a WPCG accredited painting contractor means works can be authorised and carried out under the operator's own safety system without delays.
How long does it take to repaint service station canopy columns?
It depends on the number of columns, their condition and the hours available. With good planning, even a large, high-volume forecourt can be completed quickly. ATD repainted the canopy columns at one of Australia's busiest service stations in two days. Heavy corrosion or extra scope, such as canopy fascias or line marking, will extend the programme.
What paint is best for service station canopy columns?
A two-pack system usually performs best, with an anti-corrosive epoxy primer and a two-pack polyurethane topcoat. It resists impact, fuel splash, UV and frequent cleaning far better than standard decorative paint, and holds brand colours longer.
Is it safe to paint near fuel dispensers?
Yes, with the right controls. Painting near dispensers must follow the site's clearance or permit system and hazardous area requirements. That includes controlling ignition sources, choosing suitable application methods, containing spills and barricading work zones away from customers and vehicles.
Can you repaint multiple service stations across different states?
Yes. ATD delivers commercial repainting from offices in Melbourne, Sydney and Brisbane, with capability in Adelaide, Perth and New Zealand. A single specification and colour-controlled program keeps every site in a fuel network consistent.
Planning a service station repaint?
Attention to Detail is a WPCG accredited commercial painting contractor, delivering live-site repainting across Australia since 2003. Our work covers fuel, retail and trade environments where downtime simply isn't an option. If we can repaint one of Australia's busiest forecourts in two days without closing it, we can build a staged programme that keeps your pumps running too.
