0 

U.S. Department 

of Transportation 

Federal Highway 

Administration 

May 29, 2020 

1200 New Jersey Ave., SE 

Washington, D.C. 20590 

In Reply Refer To: 

HSST-1/WZ-409 

Mr. Henry A. Ross 

Plasticade 

100 Howard Avenue 

Des Plaines, IL 60018 

USA 

Dear Mr. Ross: 

This letter is in response to your February 24, 2020 request for the Federal Highway 

Administration (FHWA) to review a roadside safety device, hardware, or system for eligibility for 

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

assigned FHWA control number WZ-409 and is valid until a subsequent letter is issued by 

FHWA 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: 

• Plasticade® Plasticade® Type I and Type II Barricade 

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 FHWA, 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 FHWA, 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, FHWA 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: Plasticade® Plasticade® Type I and Type II Barricade 

Type of system: Work Zone 

Test Level: MASH Test Level 3 (TL3) 

Testing conducted by: Texas A&M Transportation Institute (TTI). 

Date of request: February 24, 2020 

FHWA concurs with the recommendation of the accredited crash testing laboratory on the 

attached form. 

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. 
3 

Standard Provisions 

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

control number WZ-409 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 FHWA to use, 

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

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

determination ofvalidity, 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 FHWA 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 
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Version 10.0 (05/16) 

Page 1 of 5 

Request for Federal Aid Reimbursement Eligibility 

of Highway Safety Hardware 

Submitter 

Date of Request: February24,2020 New Resubmission 

Name: HenryA.Ross 

Company: Plasticade 

Address: 100HowardAvenue,DesPlaines,IL60018 

Country: U.S.A. 

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&TestingCriterion-Enter from right to left starting with TestLevel ! -! - ! ! -! -! 

SystemType SubmissionType DeviceName / Variant TestingCriterion Test 

Level 

'WZ':CrashWorthyWorkZon PhysicalCrashTesting 

Engineering Analysis 

Plasticade®TypeIand 

TypeIIBarricade 

AASHTOMASH 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: HenryA.Ross SameasSubmitter 

CompanyName: Plasticade SameasSubmitter 

Address: 100Howard Avenue,DesPlaines,IL60018 SameasSubmitter 

Country: U.S.A. SameasSubmitter 

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

Eligibility Process for Safety Hardware Devices' document. 

TexasA&MTransportation Institute(TTI)wascontracted byPlasticade®toperform full-scalecrash testing of the 

Plasticade®TypeIandTypeIIBarricade. Therearenoshared financial interests in thePlasticade®TypeIand 

TypeIIBarricadebyTTI,or betweenPlasticade®andTTI,other thancostsinvolved in theactual crash testsand 

reportsfor thissubmission toFHWA. 

690900-PLP7&8 
I 

r- r 

Version 10.0 (05/16) 

Page 2 of 5 

PRODUCT DESCRIPTION 

New Hardware or Modification to 

Significant Modification ExistingHardware 

ThePlasticade®TypeIandTypeIIBarricade is40 inchestall,25 incheswide,and43 incheslong.The testarticle 

consisted of two main components made from High Density Polyethylene (HDPE) plastic connected at the 

hinges. A safety light (Empco-Lite Model 2006 with four D-cell batteries) wasattached to the top of the test 

article, bringing the total height of thebarricadeto 47.3inchesto the top of thesafety light.The testarticle 

weighed27 lb (including 10lb of internal ballast sandand the3-lbsafetylight) plus one35lb sand bag placed 

over onelower leg. 

CRASH TESTING 

Bysignaturebelow, theEngineeraffiliated with the testing laboratory, agreesin support of thissubmission 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 testsare necessary to determine the device meets 

theMASH criteria. 

Engineer Name: D.LanceBullard,Jr.,P.E. 

EngineerSignature: 

Address: 3100SH47,Bldg 7091,Bryan,TX,77807 SameasSubmitter 

Country: U.S.A. SameasSubmitter  A brief description of each crash test and its result:

D.LanceBullard,Jr. Digitally signed by D.LanceBullard,Jr. 

Date:2020.03.02 08:39:53-06'00' 

RequiredTest 

Number 

Narrative 

Description 

Evaluation 

Results 

3-70(1100C) 

3-70 MASHstatesthat Test3-70 forsmall 

vehicles is considered optional for workzone traffic control devices weighing less 

than 220 lb, because velocity changes 

during low-speed impacts with freestanding, lightweight featureswill be within 

acceptable limits. The Plasticade®Type I 

and Type II Barricade traffic control device 

weighed 27 lb (including 10 lb of internal 

ballast sand and the 3-lb safety light), 

exclusiveof thesandbags.Therefore,MASH 

Test 3-70 was not performed on this traffic 

control device. 

Non-Critical,not conducted 
 

 

 

Version 10.0 (05/16) 

Page 3 of 5 

RequiredTest 

Number 

Narrative 

Description 

Evaluation 

Results 

3-71(1100C) 

3-71 MASHTest3-71 involved an 1100C 

vehicle weighing 2420 lb ±55 lb impacting 

the trafficcontrol deviceat an impactspeed 

of 62 mi/h ±2.5 mi/h. Per MASH 

recommendations,the device wastestedat 

critical impactangles(CIAs)of 90°±1.5°and 

0°±1.5°. 

Theresultsof test690900-PLP7conducted 

onOctober 25,2019arefoundin TTITest 

Report number 690900-PLP7&8. The test 

vehicle wastravelingat an impactspeedof 

61.6 mi/h when it contacted the first 

barricade at an impact angle of 0°. The 

vehicle wastravelingat an impactspeedof 

59.7 mi/h and impact angle of 90° when it 

contacted thesecondbarrier.Brakeson the 

vehicle were applied after loss of contact 

with the second barricade, and the vehicle 

came to rest 315 ft downstream of the 

impact. The barricades fractured into 

numerouspieces.Thedebrisfield extended 

from 37 ft to 165 ft downstream of impact 

and from 25 ft to the left and 7 ft to the 

right of thevehicle path.Thefront bumper 

and hood were damaged.Thehood 

sustainedfoursmalldeformation areas,one 

6 inches × 5 inches × 0.5 inch deep on the 

right side,asecond3 inches× 5 inches×

0.25inch near front center, third 14 inches×

14 inches× 0.5inchat theleft,andafourth 

7 inches × 2 inches × 0.25 inch at the left 

rear. There was no damage to the 

windshield. No occupant compartment 

deformation or intrusion wasobserved. 

MASH does not require instrumentation of 

the vehicle when impacting lightweight, 

freestanding work zone traffic control 

devicesweighing lessthan 220 lb, therefore 

the occupant risk factors were not 

calculated for this test.ThePlasticade®Type 

I and Type II Barricade weighed 27 lb 

(including10 lb of internal ballastsandand 

the 3-lb safety light), exclusive of the 

sandbags. 

ThePlasticade®TypeIandTypeIIBarricade 

performed acceptably for MASH test 3-71 

with impactanglesof 0°and90°. 

PASS 
3-72(2270P) 

MASHTest3-72 involvesa2270Pvehicle 

weighing 5000 lb ±110 lb impacting the 

trafficcontrol deviceat an impactspeedof 

62 mi/h ±2.5 mi/h. Per MASH 

recommendations,thedevice wastestedat 

critical impactangles(CIAs)of 90°±1.5°and 

0°±1.5°. 

Theresultsof test690900-PLP8conducted 

onOctober 25,2019arefoundinTTITest 

Report number 690900-PLP7&8. The test 

vehicle wastravelingat an impactspeedof 

61.7 mi/h when it contacted the first 

barricade at an impact angle of 0°. The 

vehicle wastravelingat an impactspeedof 

60.6 mi/h and impact angle of 90° when it 

contacted thesecondbarrier.Brakeson the 

vehicle were applied after loss of contact 

with the second barricade, and the vehicle 

came to rest 395 ft downstream of the 

impact. The first barricade fractured into 

numerous pieces with a debris field 

extending from48ft to 118ft downstream 

of impactand from4 ft to 12ft to theright 

of the vehicle path. The second barricade 

remained intact (besides the safety light) 

andcameto rest192ft downstreamand3 ft 

to theright of thevehicle path.Thegrill and 

hood were damaged. The hood sustained 

one small area of deformation. There was 

no damage to thewindshield. No occupant 

compartment deformation or intrusion was 

observed. 

MASH does not require instrumentation of 

the vehicle when impacting lightweight, 

freestanding work zone traffic control 

devicesweighing lessthan220lb, therefore 

the occupant risk factors were not 

calculated for this test.ThePlasticade®Type 

I and Type II Barricade weighed 27 lb 

(including10 lb of internal ballastsandand 

the 3-lb safety light), exclusive of the 

sandbags. 

ThePlasticade®TypeIandTypeIIBarricade 

performed acceptably for MASH test 3-72 

with impactanglesof 0°and90°. 

PASS 

Version 10.0 (05/16) 

Page 4 of 5 

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: TexasA&MTransportation Institute 

LaboratorySignature: Digitally signed by DarrellL.Kuhn 

'Date:2020.02.2816:40:36-06'00 

Address: 3100SH47,Bldg 7091,Bryan,TX,77807 SameasSubmitter  Country: U.S.A SameasSubmitter  Accreditation Certificat

Number and Dates of current

Accreditation period : 

ISO17025-2017Laboratory 

A2LACertificate Number:2821.01 

ValidTo:April 30,2021 

DigitallysignedbyHenryRoss 

Date:2020.03.0316:26:05 

-06'00' 

SubmitterSignature*: HenryRoss

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 
0.000 s 0.100 s 

.' • 

w 

0.300 s 0.600 s 

Top Panel 

12" X 24" 

40" 

Bottom Panel 

8" x24" 

25" 

Front View Side View 

Drawin s do not include safet Ii ht 

General Information 

Test Agency ........................ Texas A&M Transportation Institute (TTI) 

Test Standard Test No........ MASH Test 3-71 at 0° and 90' 

TTI Test No. .............. 690900-PLP7 

Test Date ............................ 2019-1 0-25 

Test Article 

Type ............. ............... ...... Work-Zone Traffic Control Device -

Type I and Type II Barricade 

Name ...... ..................... ...... Plasticade® Type I and Type II 

Installation Height/Weight ... 47.3 inches / 27 lb (both include light) 

Material or Key Elements .... HDPE legs, HOPE boards, safety light, 

and one 35-lb sand bag 

0 Soil Type and Condition ...... Concrete pavement, damp 

N 

N 

0 

I 

0 

N 

I 

Test Vehicle 

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

Make and Model. ................. 201 1 Kia Rio 

Curb ....................................2343 lb 

Test Inertial ......................... 2441 lb 

Dummy ................................165 lb 

Gross Static ........... 2606 lb 

Impact Conditions 

Speed Barricade #1 ............61 .6 mi/h 

Angle Barricade #1 .............. 0' 

Speed Barricade #2 .. ......... . 59. 7 mi/h 

Angle Barricade #2 .............. 90° 

Kinetic Energy #1 & #2 ......... 310 & 291 kip-ft 

Exit Conditions 

Speed Barricade #1 ............ 59.7 mi/h 

Speed Barricade #2 ............ 57.7 mi/h 

Post-Impact Trajectory 

Stopping Distance ......................... 315 ft downstream 

Maximum Test Debris Scatter 

Barricade #1 ........................ ........ 37 to 165 ft 

downstream 

Vehicle Damage 25 ft left/7 ft right 

VDS .............................................. . 

CDC ........................ ... ......... ........... 12FD1 

Max. Exterior Deformation ............. 12FDEN1 

OCDI. ............................................. 0.5 inch 

Max. Occupant Compartment FS00000OO 

Deformation ..................... . 

Windshield Damage .. . .. . ...... None 

None 

w Figure 5.6. Summary of Results for MASH Test 3-71 at 0° and 90° on Plasticade® Type I and Type II Barricades. 
...., 

:,::; 

z 

0 

°' \0 

0 

\0 

0 

0 

I 

""O 

~ -....J 0.000 s 0.200 s 0.300 s 0.500 s Re> 

00 

Top Panel 

12" X 24" 

40'' ,. Bottom Panel 

[[JJ • 8"x 24"

\0 

25" 

Front View Side View 

Drawin s do not include safet Ii ht 

General Information 

Test Agency ............... ........ Texas A&M Transportation Institute (TTI) 

Test Standard Test No ........ MASH Test 3-72 at o• and 90° 

TTI Test No. ................... 690900-PLPS 

Test Date .... ........................ 2019-10-25 

Test Article 

Type .................................. Work-Zone Traffic Control Device -

Type I and Type II Barricade 

Name............................. ..... Plasticade«> Type I and Type II Barricade 

Installation Height/Weight ... 47.3 inches/ 27 lb (both include light) 

Material or Key Elements .... HOPE legs, HOPE boards, safety light, 

and one 35-lb sand bag 

0 Soil Type and Condition ...... Concrete pavement, damp 

N 

N 

0 

I 

0 

N 

I

-

Test Vehicle 

Type/Designation ................2270P 

Make and Model .................. 2014 RAM 1500 

Curb ....................................4977 lb 

Test Inertial ......................... 5062 lb 

Dummy ................................ No dummy 

Gross Static......................... 5062 lb 

Impact Conditions 

Speed Barricade #1 ............ 61.7 mi/h 

Angle Barricade #1 .............o• 

Speed Barricade #2 .... ........ 60.6 mi/h 

Angle Barricade #2 .............. 90° 

Kinetic Energy #1 & #2.........644 & 621 kip-ft 

Exit Conditions 

Speed Barricade #1 ............60.6 mi/h 

Speed Barricade #2 ............ 59.8 mi/h 

Post-Impact Trajectory 

Stopping Distance .............. ........... 395 ft downstream 

Maximum Test Debris Scatter 

Barricade #1 ................................ 48 to 118 ft 

downstream 

Barricade #2 .......................... ...... 4 to 12 ft right 

192 ft downstream 

Vehicle Damage 3 ft right 

VOS .............................. 

CDC ............................ ................... 12FD1 

Max. Exterior Deformation ............. 12FDEW1 

OCDI .............................................. None 

Max. Occupant Compartment FSOOOOOOO 

Deformation ............................. . 

Windshield Damage ...... ................ None 

None 

w Figure 6.7. Summary of Results for MASH Test 3-72 at 0° and 90° on Plasticade® Type I and Type II Barricades.