December 27, 20 19 

 1200 New Jersey Ave., SE

  Washington, D.C. 20590

In Reply Refer To: 

HSST-1 /WZ-385 

Mr. Felipe Almanza 

TrafFix Devices Inc. 

160 A venida La Pata 

San Clemente California 92673 

Dear Mr. Almanza: 

This letter is in response to your March 28, 2019 request for the Federal Highway Administration 

(FHW A) to review a roadside safety device, hardware, or system for eligibility for 

reimbursement under the Federal-aid highway program. This FHW A letter of eligibility is 

assigned FHW A control number WZ-385 and is valid until a subsequent letter is issued by 

FHW A that expressly references this device. 

Decision 

The following device is eligible within the length-of-need, with details provided in the form 

which is attached as an integral part of this letter: 

• Big Buster Sign Stand 

Scope of this Letter 

To be found eligible for Federal-aid funding, new roadside safety devices should meet the crash 

test and evaluation criteria contained in the American Association of State Highway and 

Transportation Officials' (AASHTO) Manual for Assessing Safety Hardware (MASH). 

However, the FHW A, the Department of Transportation, and the United States Government do 

not regulate the manufacture of roadside safety devices. Eligibility for reimbursement under the 

Federal-aid highway program does not establish approval, certification or endorsement of the 

device for any particular purpose or use. 

This letter is not a determination by the FHW A, the Department of Transportation, or the United 

States Government that a vehicle crash involving the device will result in any particular 

outcome, nor is it a guarantee of the in-service performance of this device. Proper 

manufacturing, installation, and maintenance are required in order for this device to function as 

tested. 

This finding of eligibility is limited to the crashworthiness of the system and does not cover other 

structural features, nor conformity with the Manual on Uniform Traffic Control Devices. 
2 

Eligibility for Reimbursement 

Based solely on a review of crash test results and certifications submitted by the manufacturer, 

and the crash test laboratory, FHW A agrees that the device described herein meets the crash test 

and evaluation criteria of the AASHTO's MASH. Therefore, the device is eligible for 

reimbursement under the Federal-aid highway program if installed under the range of tested 

conditions. 

Name of system: Big Buster Sign Stand 

Type of system: Work Zone 

Test Level: MASH Test Level 3 (TL3) 

Testing conducted by: KARCO 

Date of request: March 8, 2019 

FHW A concurs with the recommendation of the accredited crash testing laboratory per the 

attached form for the above device using a 48" x 48" aluminum substrate sign. 

Full Description of the Eligible Device 

The device and supporting documentation, including reports of the crash tests or other testing 

done, videos of any crash testing, and/or drawings of the device, are described in the attached 

form. 

Notice 

This eligibility letter is issued for the subject device as tested. Modifications made to the device 

are not covered by this letter. Any modifications to this device should be submitted to the user 

(i.e., state DOT) as per their requirements. 

You are expected to supply potential users with sufficient information on design, installation and 

maintenance requirements to ensure proper performance. 

You are expected to certify to potential users that the hardware furnished has the same chemistry, 

mechanical properties, and geometry as that submitted for review, and that it will meet the test 

and evaluation criteria of AASHTO's MASH. 

Issuance of this letter does not convey property rights of any sort or any exclusive privilege. This 

letter is based on the premise that information and reports submitted by you are accurate and 

correct. We reserve the right to modify or revoke this letter if: (1) there are any inaccuracies in 

the information submitted in support of your request for this letter, (2) the qualification testing 

was flawed, (3) in-service performance or other information reveals safety problems, ( 4) the 

system is significantly different from the version that was crash tested, or (5) any other 

information indicates that the letter was issued in error or otherwise does not reflect full and 

complete information about the crashworthiness of the system. 

Standard Provisions 
3 

Standard Provisions 

• To prevent misunderstanding by others, this letter of eligibility designated as FHW A 

control number WZ-385 shall not be reproduced except in full. This letter and the test 

documentation upon which it is based are public information. All such letters and 

documentation may be reviewed upon request. 

• This letter shall not be construed as authorization or consent by the FHW A to use, 

manufacture, or sell any patented system for which the applicant is not the patent holder. 

• This FHWA eligibility letter is not an expression of any Agency view, position, or 

determination of validity, scope, or ownership of any intellectual property rights to a 

specific device or design. Further, this letter does not impute any distribution or licensing 

rights to the requester. This FHW A eligibility letter determination is made based solely 

on the crash-testing information submitted by the requester. The FHW A reserves the 

right to review and revoke an earlier eligibility determination after receipt of subsequent 

information related to crash testing. 

Sincerely, 

Michael S. Griffith 

Director, Office of Safety Technologies 

Office of Safety 

Enclosures 
Version 10.0 (05/16) 

Page 1 of 5 

Request for Federal Aid Reimbursement Eligibility 

of Highway Safety Hardware 

Date of Request: February 21, 2019 I r- New r Resubmission 

Name: Robert Ramirez 

... 

...

...

a,

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Company: 

Address: 

Country: 

TrafFix Devices, Inc. 

160 Ave La Pata, San Clemente, CA 92673 

United States 

To: Michael S. Griffith, Director 

FHWA, Office of Safety Technologies 

I request the following devices be considered eligible for reimbursement under the Federal-aid 

highway program. 

Device & Testing Criterion - Enter from right to left starting with Test Level Fl 

System Type Submission Type Device Name/ Variant Testing Criterion Test 

Level 

'WZ': Crash Worthy Work 

Zone Traffic Control Devices 

(e Physical Crash Testing 

(' Engineering Analysis Big Buster Sign Stand 

AASHTO MASH TL3 

By submitting this request for review and evaluation by the Federal Highway Administration, I certify 

that the product(s) was (were) tested in conformity with the AASHTO Manual for Assessing Safety 

Hardware and that the evaluation results meet the appropriate evaluation criteria in the MASH . 

Individual or Organization responsible for the product: 

Contact Name: Robert Ramirez Same as Submitter 1:8:J 

Company Name: TrafFix Devices, Inc. Same as Submitter 1:8:J 

Address: 160 Ave La Pata, San Clemente, CA 92673 Same as Submitter 1:8:J 

Country: United States Same as Submitter 1:8:J 

Enter below all disclosures of financial interests as required by the FHWA ' Federal-Aid Reimbursement 

Eligibility Process for Safety Hardware Devices' document. 

TrafFix Devices Inc. and Appl us IDIADA Karco Engineering LLC share no financial interests between the two 

organizations. This includes no shared financial interest but not limited to: 

i. Compensation including wages, salaries, commissions, professional fees, or fees for business referrals 

iii. Research funding or other forms of research support; 

iv. Patents, copyrights, licenses, and other intellectual property interests; 

vi. Business ownership and investment interests; 
Version 10.0 (05/16) 

Page 2 of 5 

PRODUCT DESCRIPTION 

(e New Hardware or 

• Significant Modification 

l Modification to 

Existing Hardware 

The TrafFix Devices Big Buster Sign Stand is a temporary work-zone device consisting of five main components: 

one steel base assembly, one outer aluminum mast, one inner aluminum telescoping mast, two rigid sign 

brackets, and one 48" x 48" x 0.080" thick aluminum sign. 

The steel base consists of a dual spring assembly at the base of the outer mast. When deployed, the aluminum 

legs form an X-footprint that has overall dimensions of 57.31 in. (1455.7 mm] x 125.25 in. (3181 .4 mm]. 

The inner mast telescopes through the outer mast and locks into place when fully extended using a push 

button. 

The rigid sign brackets are designed hold the aluminum sign in place. The sign is removed by loosening one of 

the rigid sign brackets to provide clearance for the sign to be lifted and removed from the sign stand. 

The Big Buster Sign Stand can be used on concrete, asphalt, gravel, or dirt surfaces. The test was conducted on 

a concrete surface. The Big Buster Sign Stand can be used with or without flags. Flags were installed for these 

tests. 

The overall dimensions of the Big Buster Sign Stand with the aluminum sign installed is approx. 57.31 in. 

(1455.7 mm] x 125.25 in. (3181 mm] x 132.0 in. (3352.8 mm]. Sand bags can be placed on the legs as needed for 

ballast. 

The MASH tested and passed Big Buster Sign Stand, described above, is based on the previously tested and 

passed NCHRP-350 Big Buster Sign Stand (Reference WZ-24, WZ-73, WZ-108, and WZ-113). 

CRASH TESTING 

By signature below, the Engineer affiliated with the testing laboratory, agrees in support of this submission that 

all of the critical and relevant crash tests for this device listed above were conducted to meet the MASH test 

criteria. The Engineer has determined that no other crash tests are necessary to determine the device meets 

the MASH criteria. 

Engineer Name: Steven Matsusaka 

Engineer Signature: Ste n MatS Digitally signed by Steven Matsusaka 

U ka DN: cn:::~teven Matsusaka, o::::~μ_plusIDIADA KARCO Engineering, LLC.,

ou, ema1l:::S teven.Matsusaka@1d1ada.com, c:::US Ve Sa Date: 2019.03.28 11 :36:31 -07'00' 

Address: 9270 Holly Rd, Adelanto, CA 92301 Same as Submitter D 

Country: United States of America Same as Submitter D 

A brief description of each crash test and its result : 

Required Test 

Number 

Narrative 

Description 

Evaluation 

Results 

Designed to evaluate the ability of a small 

car to activate any breakaway, fracture or 

yielding mechanism. Test 3-70 is considered 

optional for work-zone traffic control 

devices weighing less than 220 lbs (100 kg). 

The as-tested Big Buster weighted 

approximately 69 lbs (31 kg) therefore the 

test was non-relevant and was not 

conducted. 

3-70 (1 l00C) Non-Relevant Test, not conducted 
Version 10.0 (05/16) 

Page 3 of 5 

Required Test 

Number 

Narrative 

Description 

Evaluation 

Results 

3-71 (1100() 

For this test, two Big Buster Sign Stands 

were impacted. The first test article was 

aligned at 90° and the second test article 

was aligned at 0° to the impacting vehicle's 

direction of travel. This test is intended to 

evaluate the sign stand's behavior when 

impacted by an 11 00C test vehicle. The 

primary evaluation is based on intrusion 

into the occupant compartment, windshield 

damage, and vehicle stability. According to 

MASH lightweight devices under 220 lbs 

(100 kg), such as the Big Buster Sign Stand 

cannot cause sufficient velocity change that 

would result in exceeding occupant risk 

criteria limits. The as-tested devices 

weighed approximately 69 lbs (31 kg), 

therefore Test 3-71 was conducted without 

instrumentation for evaluating occupant 

risk values. 

The test was conducted using a 

commercially available 2014 Hyundai 

Accent 4 door sedan with a test inertial 

mass of 2,412.9 lbs. (1,094.5 kg). The test 

vehicle impacted the first sign stand 

(oriented at 90°) at a velocity of 63.45 mph 

(102.12 km/h). Upon impact the springs 

were activated as the outer mast folded 

over the front of the vehicle. The aluminum 

sign released from the mast upon impact. 

The top of inner mast contacted the 

windshield and roof on the driver side of 

the vehicle. 

The test vehicle continued along its path 

and impacted the second sign stand 

(oriented at 0°) at a velocity of 61.16 mph 

(98.43 km/h). Upon impact the springs were 

activated as the mast began to fold over the 

vehicle. The aluminum sign separated from 

the mast as the mast broke off at the 

breakaway point. 

The vehicle's occupant compartment was 

not penetrated by the test articles and the 

intrusion limits did not exceed the MASH 

allowable limits. Debris from the test articles 

did not block the driver's vision. The vehicle 

remained upright and the roll angle did not 

exceed 75°. The vehicle cleared both 

devices in a controlled and stable manner. 

The Big Buster Sign Stand met all the 

requirements for MASH Test 3-71. 

PASS 
Version 10.0 (05/16) 

Page 4 of 5 

3-72 (2270P) 

For this test, two Big Buster Sign Stands 

were impacted. The first test article was 

aligned at 90° and the second test article 

was aligned at 0° to the impacting vehicle's 

direction of travel. This test is intended to 

evaluate the sign stand's behavior when 

impacted by a 2270P test vehicle. The 

primary evaluation is based on intrusion 

into the occupant compartment, windshield 

damage, and vehicle stability. According to 

MASH lightweight devices under 220 lbs 

(100 kg), such as the Big Buster Sign Stand 

cannot cause sufficient velocity change that 

would result in exceeding occupant risk 

criteria limits. The as-tested devices 

weighed approximately 69 lbs (31 kg), 

therefore Test 3-72 was conducted without 

instrumentation for evaluating occupant 

risk values. 

The test was conducted using a 

commercially available 2012 RAM 1500 4 

door pickup with a test inertia mass of 

4,955.9 lbs. (2,248.0 kg). The test vehicle 

impacted the first sign stand (oriented at 

90°) at a velocity of 63.09 mph (101.53 km/ 

h). Upon impact the springs were activated. 

The aluminum sign released from the sign 

stand as the mast bent around the vehicle's 

front profile. The sign contacted and 

damaged both the windshield and the roof. 

The test vehicle continued along its path 

and impacted the second sign stand 

(oriented at 0°) at a velocity of 60.44 mph 

(97.27 km/h). Upon impact the springs were 

activated, and the mast broke away from 

the outer mast. The aluminum sign 

separated from the mast and contacted the 

windshield and roof but caused no damage. 

The vehicle's occupant compartment was 

not penetrated and the intrusion limits did 

not exceed the MASH allowable limits. 

Debris from the test articles did not block 

the driver's vision. The vehicle remained 

upright and the roll angle did not exceed 

75°. The vehicle cleared both devices in a 

controlled and stable manner. The Big 

Buster Sign Stand met all the requirements 

for MASH Test 3-72. 

PASS 

Full Scale Crash Testing was done in compliance with MASH by the following accredited crash test 

laboratory (cite the laboratory's accreditation status as noted in the crash test reports.) : 
Version 10.0 (05/16) 

Page 5 of 5 

Laboratory Name: Appl us IDIADA KARCO Engineering, LLC. 

Laboratory Signature: 

Digitally signed by Steven Matsusaka 

DN: cn =Steven Matsusaka, o=Applus IDIADA KARCO Engineering, LLC., ou, Steven Matsusaka email =Steven.Matsusaka@idiada.com, c=US 

Date: 2019.03.28 11 :37:4 7 ~07'00' 

Address: 9270 Holly Rd, Adelanto, CA 92301 Same as Submitter D 

Country: United States of America Same as Submitter D 

Accreditation Certificate 

Number and Dates of current 

Accreditation period : 

TL-371 , September 14, 2018 - July 1, 2019 

Submit Form 

ATTACHMENTS 

Attach to this form: 

1) Additional disclosures of related financial interest as indicated above. 

2) A copy of the full test report, video, and a Test Data Summary Sheet for each test conducted in 

support of this request. 

3) A drawing or drawings of the device(s) that conform to the Task Force- 13 Drawing Specifications 

[Hardware Guide Drawing Standards]. For proprietary products, a single isometric line drawing is 

usually acceptable to illustrate the product, with detailed specifications, intended use, and contact 

information provided on the reverse. Additional drawings (not in TF-13 format) showing details that 

are relevant to understanding the dimensions and performance of the device should also be submitted 

to facilitate our review. 

FHWA Official Business Only: 

Eligibility Letter 

Number Date Key Words 
• • 

MASH 2016 Test 3-72 Summary 

90° CIA 0° CIA 

0.000 s 0.100 s 0.250 s 0.679 s 0.750 s 0.950 s 

Debris: • 

• • 

• 

3,1ft, --.--

• • 

-----------------------------------,2965 ft (90 4e,I----- --- -------------------------~ 

GENERAL INFORMATION 

Test Agency ..... ...... ........ KARCO Engineering, LLC. 

KARCO Test No ....... P37378-02 

Test Designation.. .. . 3-72 

Test Date .. ..... ... . . 11/16/17 

TEST ARTICLE 

Name I Model .. . Big Buster 

Type .. .. ....... ......... Work Zone Device 

Device Height . .... .. ..... .... . 14.2 ft. (4.3 m) 

Key Elements ..... Mast,base,AI substrate 

Road Surface .......... ....... Concrete 

TEST VEHICLE 

Type I Designation . .......... 2270P 

Year, Make, and Model. .... 2012 RAM 1500 

Curb Mass ... .. .. 4,799.4 lbs (2,177.0 kg) 

Test Inertial Mass .. .... ..... .. 4,955.9 lbs (2,248.0 kg) 

Gross Static Mass ............ 4,955.9 lbs (2,248.0 kg) 

Figure 2 Summary of Test 3-72 

Impact Conditions 

Impact Velocity Device 1.... 63.09 mph (101 .53 km/h) 

Impact Velocity Device 2 ... . 60.44 mph (97.27 km/h) 

Device 1 Angle ................ 90° 

Device 2 Angle ................ o• 

Device 1 Kinetic Energy .... . 659.7 kip-ft (894.4 kJ) 

Device 2 Kinetic Energy ..... 605.5 kip-ft (820.9 kJ) 

Exit Conditions 

Device 1 Exit Velocity ........ 61 .34 mph (98.72 km/h) 

Device 2 Exit Velocity .58.27 mph (93. 78 km/h) 

Vehicle Resting Position .. ... 296.5 ft. (90.4 m) Downstream 

3.1 ft . (1 .0 m) Right 

Vehicle Stability . Satisfactory 

Maximum Roll Angle .. . N/A* 

Maximum Pitch Angle ....... NIA* 

Maximum Yaw Angle ......... N/A* 

Occupant Risk* 

Longitudinal OIV ................. N/A 

Lateral OIV...... .. . N/A 

Longitudinal RA ...... .. .... ...... N/A 

Lateral RA .... ... ..... .... .... ..... N/A 

THIV................. .. ...... ... .... . N/A 

PHO ............. . .. ....... N/A 

ASI. ................................. N/A 

Test Article Deflections 

Debris Field (longitudinal) ...... 285.7 ft. (87.1 m) 

Debris Field (lateral) ......... .... 20.1 ft. (6.1 m) 

Vehicle Damage 

Vehicle Damage Scale . N/A 

CDC.. . .. . N/A 

Maximum Intrusion .. .. .. . 1.6 in. (41 mm) 

• Not Applicable, device weighs lass than 220 lbs (100 kg) 

13 TR-P37378-02-NC 
MASH 2016 Test 3-71 Summary 

90° CIA 0° CIA 

- ~ - nao.,~. 

0.300 s 0.075 s 0.000 s 0.836 s 0.738 s 0.676 s 

GO 716ft r'L. ~ [:: Debr- ,s: • 

~--------------------~ ---356 Ift [108 5,-,1-------------------------

GENERAL INFORMATION 

Test Agency .................... IDIADA KARCO 

KARCO Test No ..... ......... P37393-01 

Test Designation .......... 3-71 

Test Date .............. .. ....... 1/4/18 

TEST ARTICLE 

Name / Model .......... .. ...... MASH Big Buster 

Type ................. ..... ... .... Work Zone Device 

Device Height ..... 14.2 ft. (4.3 m) 

Key Elements . ...... .. ....... Mast.base, Al substrate 

Road Surface...... .. ... ...... . Concrete 

TEST VEHICLE 

Type / Designation ........... 11 00C 

Year, Make, and Model ..... . 2014 Hyundai Accent 

Curb Mass ... ................... 2,412.9 lbs (1 ,094.5 kg) 

Test Inertial Mass .... 2,412.9 lbs (1 ,094.5 kg) 

Gross Static Mass ............ 2,584.9 lbs (1,172.5 kg) 

Figure 3 Summary of Test 3-71 

Impact Conditions 

Impact Velocity Device 1 ... 63.45 mph (102.12 km/h) 

Impact Velocity Device 2 .... 61 .16 mph (98.43 km/h) 

Device 1 Angle ................. 90° 

Device 2 Angle .. .. .. .... . 0° 

Device 1 Kinetic Energy ...... 324.8 kip-ft (440.4 kJ) 

Device 2 Kinetic Energy ...... 301 . 7 kip-ft (409.1 kJ) 

Exii_C_Q_n d itio ns 

Device 1 Exit Velocity ...... .. 61 .9 mph (99.6 km/h) 

Device 2 Exit Velocity ..... ... 59. 7 mph (96.1 km/h) 

Vehicle Resting Position .... 356.1 ft. (108.5 m) Downstream 

71.6 ft. (21 .8 m) Left 

Vehicle Stability .. .. . . Satisfactory 

Maximum Roll Angle ......... NIA* 

Maximum Pitch Angle .. N/A* 

Maximum Yaw Angle ........ NIA* 

Occupant Risk 

Longitudinal OIV ...... ...... .. .... N/A* 

Lateral OIV ......... NIA* 

Longitudinal RA....... .. .. .. .. . N/A* 

Lateral RA.... ... N/A* 

THIV ................. ....... ... ..... N/A* 

PHO .......... .. .... N/A* 

ASI. . ..................... ..... .. .... N/A* 

Test Article Deflections 

Debris Field (longitudinal) ... .. 297.7 ft. (90.7 m) 

Debris Field (lateral).. 38.9 ft. (11 .9 m) 

Vehicle Damage 

Vehicle Damage Scale.. .... .. .. 12-FD-0 

CDC...... . 12FDEN0 

Maximum Intrusion.............. 0.9 in. (23 mm) 

• Not Applicable, device weighs less than 220 lbs (1 00 kg) 

13 TR-P37393-01-NC 
D D

C C

APPROX. 170.0 

48.0 

~ 4318] [1219 .20] 

SQUARE SIGN 

132.0 

[3352.80] 

60:00 

[1524] 

FROM GROUND LEVEL 

TO BOTTOM OF SI :;N 

~ 

l UNlESS OTHERWISE SPECIFIED : All 01MENS10NS ARE IN INCHESjmm) . 

TOLERANCES · 160 Avemda La Pata TrafFix dJ, S.m Clcrm1111c, CA 92673 

DECIMAL: X.X !: .0625" (949) 36 1-5663 X.XX t .032 

fR ...CTIO~lAL X/X ! 1/16 (1.omm] 

X.XXX!.015 

Devices Inc. ~ ~(,~W,x!!~;i;~~om DEGREES; ! 0.5• 

TITLE: 

A A 

Big Buster Sign Stand 

SIZE DWG. NO. REV 0RAWN8Y: DATE: Ct'Yi1tophe1 Jome 11/15/17 

CHECt'.EDBY: DATE: FA 11/15/17 

APPROVED BY DATE: 

l. Units: Inches [mm] B 500-204 A 

NOTES: UNLESS OTHERWISE SPECIFIED FA 11/1S/!7 SHEET I OF I 

8 3 2