MAINTENANCE OF SIGNS

AND SIGN SUPPORTS

FOR LOCAL ROADS AND STREETS

A Guide for

Street and Highway Maintenance Personnel

U.S. Department

Of Transportation

Federal Highway

Administration

Office of Highway Safety

FHWA-RT-00-00
TABLE OF CONTENTS

Page

I. Importance of Maintaining the Sign Face 1

General information 2

Regulatory signs 3

Warning signs 4

Guide signs 5

Work zone and special signing 6

II. Repair and Replacement of Sign Panels 7

Bent and damaged signs 7

Accident and damaged signs and sign supports 8

Simple maintenance 9

Damaged signs 10

Field repair of bent signs 11

Field repair of scrapes and holes 12

Field repair of damaged signs 13

Vandalized signs 15

Vegetation clearing 20

Missing signs 21

Illegible and nonreflective signs 24

General procedures in the repair and maintenance

of signs 25

III. Repair and Replacement of Small Sign Supports 27

Location and height of signs 27

Positioning signs 29

Crash worthy sign supports 32

Unsafe practices 36

IV. Cleaning and Checking Signs and Sign Supports 38

V. Materials and Equipment Used in 

Maintaining Signs 39

Sign posts

Handtools 41

Prepared under the Local Transportation Assistance

Program for use by Technology Transportation Centers

Notice

This document is disseminated under the

sponsorship of the Department of Transportation

in the interest of information exchange. The

United States Government assumes no liability for

its content or use thereof.

The contents of this report reflect the predominant

views of City, State and federal authorities at the

time of publication and as such are technical

opinions on best methods of approaching current

technical issues. The opinions expressed herein

should therefore not be construed as Federal or

State policies. The contents do not necessarily

reflect the official policy of the Department of

Transportation.

This report does not constitute a manual,

handbook, standard, specification, or regulation.

The United States Government does not endorse

products or manufacturers. Trademarks or

manufacturer’s names appear herein only because

they are considered essential to the objective of 

this document.
I. IMPORTANCE OF MAINTAINING

THE SIGN FACE

This handbook is intended to help maintenance workers

understand the importance of well maintained signs and provide

information that will help them in accomplishing that task. Well

maintained signs are important to drivers in making good

decisions. 

Many signs require or advise the drivers to take specific actions.

These signs must be clean, legible, used correctly and in good

condition to command the respect of a driver. 

There are three major kinds of signs that provide the driver with

the “Rules of the Road” and provide guidance and information for

efficient traffic flow.

• Regulatory

• Warning

• Guide

There are also special signs for use in work zones or to direct

people to special events, but they all fit into these three catagories.

VI. Traffic Control During Sign Maintenance 42

Shoulder work with minor encroachment 42

Lane closure on two-lane road using flaggers 44

Lane closure on low-volume two-lane road 46

VII. Sign Maintenance Records 48

Maintenance records 48

Sign inventory 49

Incident reports 50

Maintenance records 51

VIII. Resource Material 52

1
I. IMPORTANCE OF MAINTAINING

THE SIGN FACE

• Regulatory signs

Regulatory signs are the most important to the driver because

they represent the laws and regulations that are enforceable.

They usually require a driver to take a specific action, such as

STOP, but can also deny the driver right of entry, such as DO

NOT ENTER. Failure to respond to a regulatory sign can

result in or contribute to a severe accident. This can occur

when a driver doesn’t see a regulatory sign or sees the sign too

late and makes an erratic movement. Missing, damaged, or

ineffective regulatory signs constitute a potential hazardous

condition.

Common regulatory signs include STOP, YIELD, SPEED

LIMIT, DO NOT ENTER, DO NOT PASS, ONE WAY,

and WRONG WAY.

Damaged or missing regulatory signs (especially STOP,

YIELD, DO NOT ENTER, ONE WAY and WRONG WAY

signs) should be replaced or repaired as soon as possible.

Generally, these signs should be replaced or repaired within

hours of the agency having notice of them missing, down, or

damaged. The date and time of notification should be

documented, and should be followed up with the date and

time the sign was repaired or replaced. 

I. IMPORTANCE OF MAINTAINING

THE SIGN FACE

• General information

Doing a good job of maintaining regulatory and warning

signs makes the road safer for all drivers. You should keep in

mind that an accident can occur because of a missing or

unreadable sign. Good sign maintenance will improve traffic

safety, reduce the chances of a lawsuit against the community,

and increase traffic capacity. Remember “TRAFFIC SIGNS

MUST HAVE A PURPOSE”- they must:

• Fulfill a need.

• Command attention and respect.

• Convey a clear, understandable message.

• Provide enough time for the driver to respond correctly.

Missing or damaged signs can be identified through accident

reporting procedures established with the police, ongoing

police observations, field reviews (particularly after wind and

ice storms), reports from citizens or observations of employees

during working hours, in travel to and from work, or at any

other time (day or night).

2 3
I. IMPORTANCE OF MAINTAINING

THE SIGN FACE

• Guide Signs

Guide signs are the third type of signs commonly used on

highways and roads. Guide signs generally provide the driver with

navigational information which, while important, is not as

important as the regulatory or warning signs. Guide signs are

usually used to help a driver get to a particular location. The

absence of a guide sign may not be noticed by a driver; however,

there are situations where the absence of a guide sign, particularly

a sign in a series of signs, can confuse a driver. Confused drivers

are much more likely to contribute to accidents because they are

“Not Focused on the Driving Task”. Additionally, confused

drivers often make erratic maneuvers, such as slowing or stopping

in the roadway, backing down ramps, or making abrupt turns.

Common guide signs include EXIT (for a location), REST

AREA, STREET NAMES, AIRPORT.

Replacement of damaged or missing guide signs should be

done as soon as possible, but not take priority over

replacement; or repairs of either regulatory or warning signs.

Maintenance of guide signs requires your judgement; if you

think the absence or damage to the guide sign could result in

driver confusion, replace it as soon as possible. If you don’t

think the sign is critical, you should repair or replace it when

practical, generally within two weeks. Again the action taken

along with the date and time it was taken should be

documented.

I. IMPORTANCE OF MAINTAINING

THE SIGN FACE

• Warning Signs

Warning signs are the second most important group of signs

because they are essential to the driver in making important

decisions on how to operate the vehicle. Warning signs provide

drivers with information that is necessary for controlling their

vehicle. The proper use and maintenance of warning signs help

prevent what is often called “OVER DRIVING THE ROAD”

because warning signs provide drivers with advanced notice of

potentially hazardous situations or conditions on the road ahead.

Common warning signs include: STOP AHEAD, YIELD

AHEAD, TURN, SHARP CURVE, RAILROAD CROSSING

AHEAD and SPEED WARNING signs.

Damaged or missing warning signs (especially speed advisory

plates, sharp curve signs, railroad crossing and stop ahead

signs) should be replaced or repaired as soon as possible.

Generally, a sign should be replaced as soon as it is identified

as being lost or damaged. As a general rule, the situation

should be corrected within three calendar days and the action

taken, date and time documented. 

4 5
II. REPA1R AND REPLACEMENT

OF SIGN PANELS

• Bent and Damaged Signs

When signs are damaged, bent or vandalized, you have to

determine if the sign should be repaired, replaced or left as is.

This is usually a field judgement-more often than not, it is

cheaper to replace a badly damaged or unreadable sign than

attempt many repairs. Consider the repair costs, remaining service

life of the sign face after repairs and the value of the sign blank

(when it is reusable) against replacing it with a new or recycled

sign. Do not leave a sign down or take a sign away and leave

nothing. Always try to have a replacement sign or sufficient

repair materials with you. If you decide a field repair is

appropriate or you have to repair the sign until a replacement sign

can be obtained, consider the following points:

Bent Signs

• Replacement

Signs may be bent like this DEAD

END sign. While many bent signs

can be read in the daylight, some bent

signs, even signs with minor bending,

are difficult to see at night because

they no longer reflect the light from

the vehicle’s headlights back to the

driver’s eyes. Minor bending like this

may be repaired by removing the sign

from the post and straightening the

sign face. 

I. IMPORTANCE OF MAINTAINING

THE SIGN FACE

• Work Zone and Special Signing

Work zone and special signing, such as those signs used at special

events to direct traffic, must be maintained and used correctly to

insure both the safety of the motorist and of the highway worker

or persons working on or adjacent to the highway. Because both

work zone and special signs often require drivers who are familiar

with the road to do something differently, it is extremely

important to use the correct signs and replace them immediately

if damaged or lost. Because work zone signs are used for both

scheduled and unscheduled activities, they must be in excellent

condition. This is particularly true of their retro-reflective surface,

which must be highly visible both day and night. Common work

zone signs include FLAGGER AHEAD, MERGE, and SPEED

LIMIT signs.

Damaged or missing work zone signs should be replaced

immediately. Because they are often used in conjunction

with existing signs, existing signs that are damaged or lost

and are important to traffic safety and control should also

be replaced immediately. It is a good practice to carry extra

common work zone signs in maintenance vehicles. To

protect the retro-reflectivity of the sign faces it is also

important to handle and store the signs properly, and always

remove or cover work zone signs when they are not needed.

6 7
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Simple Maintenance

• Repairs

This sign is adequate under

normal conditions but when

tampered with, it can induce a

lack of respect in the driver,

additionally the drivers

attention is diverted from the

warning message. Local

community employees should

be trained to report or resolve

such conditions immediately.

This sign is old and and the

surface is seriously cracked – it

has lost its retrorefflective

characteristic and appears as a

distorted image at night. If the

signs are still appropriate they

should be scheduled for

replacement.

Cracked, crazed, or faded sign

faces do not provide adequate

night time retroreflectivity

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Accident Damaged Signs and Sign Supports

• Replacement

The sign face is cracking. 

Retroreflective surfaces that 

have splits, breaks, peels, or

separations shoud be replaced 

as soon as practical with a new sign. 

Sign supports should be repaired or

replaced to original conditions.

This “breakaway” support was

propped up with a diagonal brace,

which could affect its safe

performance if it were hit again.

When a sign requires repeated maintenance, consideration

should be given to the reason why and the possibility of 

relocation considered.

8 9
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Field Repair of Bent Signs

A bent sign can often be fixed simply by straightening. If after

straightening the message remains clear, legible, retro-reflective

and the sign surface is not opened, cracked or separated from the

sign face, it may be reused. Remember, if a sign is so badly bent

that it will take several hours to fix, it is often cheaper to replace

the sign and leave any repair or salvage to a shop operation. To

repair a sign with minor bends, you should:

1. First try to straighten the sign. If possible, bend the sign

back in place on the sign post with hand pressure (wear

leather gloves).

2. If the sign can’t be straightened sufficiently with hand

pressure, remove the sign from the support and place it on

a flat surface such as a truck bed, trailer bed, or fender

dolly. Use cardboard or cloth to protect the sign face and

pound it flat with a rubber mallet. ( The cloth and rubber

mallet will minimize further damage to the reflective

sheeting.)

3. You must use your judgement to determine if the sign

remains serviceable; remember, this means it is legible both

day and night (retroreflective) and there is no cracking or

separation of the sheeting material.

4. If, in your opinion, the sign is no longer serviceable replace

it immediately. If no sign is available at the site, remount

the existing sign until you return later with a satisfactory

replacement.

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Damaged Signs

Damaged signs are often more than just bent signs. They can be

damaged as a result of natural actions, accidents, or vandalism.

• Natural action, such as exposure to sunlight, can result in

color fading, discoloration, and loss of the retroreflective

characteristics.

• Accidents can result in bends and scrapes that remove part

of the retroreflective material or the message on the sign,

additionally bullet holes, dings, and peeled, worn, or

separated surfaces can make a sign difficult to read.

• Vandalized signs are usually either missing or over-sprayed

with paint.

Signs may also be considered damaged if, because of their

retroreflective characteristics and orientation, they cannot be 

seen at night. These signs sustained both physical and chemical

damage and are no longer visible at night. Additionaly they

should be mounted (remounted) at the appropriate height. 

While some signs may be repairable in the field, most will require

removal (and replacement), restoration or salvage.

10 11
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Field Repair of Damaged Signs

2. Clean the area(s) to be patched with Xylol, then Varnish

naphtha.

3. If you carry replacement sign faces or patching materials,

make sure that the retroreflective material being used for

patching is the same as the material on the face of the sign.

There are different grades of retro-reflective sheeting;

generally the manufacturer’s material will have a certain

mark or pattern which will allow you to determine the type

of retroreflective material on the sign face. (It is important

to use the same retroreflective materials to ensure the sign

will remain legible at night.) If in doubt about what type of

sheeting to use replace the sign.

4. Follow the manufacturer’s recommendations. Cut

background field patches slightly larger than the damaged

area. Pressure sensitive material should be extended at least

1/2-inch beyond the damaged area.

5. Replace the damaged legend with diecut, pressure sensitive,

pre-spaced letters, borders and symbols and firmly squeegee

into place.

6. Seal the hole on the back of the sign by applying aluminum

foil tape to stop moisture from reaching the adhesive on the

sign sheeting patch. For large holes, start placing the foil at

the bottom of the hole, overlapping about 1/2-inch in a

shingle fashion as you move up covering the hole.

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Field Repair of Scrapes and Holes

Signs with scraped faces (usually as a result of being hit) or signs

that have holes in them (occasionally as a result of vandalism) are

often no longer legible, particularly at night. The damaged areas

no longer reflect light back to the driver. These signs often cannot

be read at night. While signs with severe damage are usually

replaced (to be repaired later in the shop), minor damage 

can often be repaired in the field.

Field patching can be done by preparing a repair kit that includes

the appropriate colors and types of new sheeting materials

(including pressuresensitive adhesive sheeting), cleaners and

sealants.

1. Once the sign has been straightened and any bullet holes

pounded flat (when necessary), new sheeting can be applied

to the face of the sign.

12 13
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Vandalized Signs

Spray Paint on Signs

This sign has been

sprayed with a light

colored paint.

Everyone who looks at

the sign notices it. At

night the message

becomes hard to read.

The safety

effectiveness of this

sign is significantly

reduced and requires

immediate attention.

Missing Signs

Missing signs are also a very significant problem. While signs can

be blown down in storms, missing signs are often removed by

individuals seeking a souvenir or engaged in what they might

consider a “Harmless Prank.” Of course a missing sign provides

no information for the driver and may create or contribute to a

potentially hazardous situation. This is particularly true when the

missing signs are regulatory or warning signs.

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Field Repair of Damaged Signs

7. If the sign is subject to snow burial and the replacement

sheeting extends to the top edge of the sign, place

transparent film along the top edge to seal out any

moisture. Of course, if signs can be relocated to an area to

avoid burial, they should be.

• Vandalized Signs

The resolution of problems associated with vandalism should be a

part of all sign maintenance programs. Sign vandalism is a growing

problem. Signs over-sprayed with paints are difficult to read,

particularly at night, and do not demand the respect and attention

of a driver. The removal of paint or other materials from the face of

a sign can and often does reduce its retroreflective characteristics and

therefore its effectiveness. Vandalism also occurs in rural areas where,

in addition to overpainting, signs may be the target of disgruntled

motorists or hunters or be taken by souvenir hunters.

14 15
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Vandalized Signs

Bullet holes and shotgun blasts may be repaired as discussed

under damaged signs.

Overpainted signs can often be cleaned but may also require

replacement. There are several approaches to overpainted signs.

All these approaches work to varying degrees to help reduce and

control this problem. Generally a combination of these

approaches is recommended for communities with recurring or

increasing vandalism problems. Although sign vandalism in some

cases seems to be an overwhelming problem, it is a situation that

cannot be ignored.

1. Paint can sometimes be removed from the face of signs

without damaging or reducing the sign’s retroreflective

properties. Several manufacturers have developed sign

protective overlays that are more tolerant to paints and

cleaning agents, and they have also developed improved

cleaners. 

2. Paint should not be removed with abrasive compounds or

implements that will leave the sign face scratched (i.e. steel

wool). After cleaning off paint, signs should be inspected

under night conditions to determine if they have retained

sufficient retroreflective characteristics to remain legible at

night. There are special electronic retro-reflectometers

available to measure the amount of light being reflected by

a sign and, when available, these devices facilitate the

inspection process; however, most of the inspection done at

the local level can also be done effectively with visual

inspection techniques.

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Vandalized Signs

Bullet hole damage

This sign has been hit by 

several gun shots. Even with the

holes the sign can be read

during the day and functions as

intended, but leaving a sign up

in this condition does not

convey a serious message and

may encourage more gun shots

to this and other signs. The sign

should be replaced or repaired as

soon as practical.

Shotgun blast damage

This sign has been struck by

several shotgun blasts. The

retro-reflective material is

severely damaged and while the

sign is still legible during the

day, it is not at night.

Sign faces that are painted, damaged as a result of shot holes, or

being struck by other objects (such as bottles) should be noted

and checked later that night to determine if their retroreflective

characteristics are acceptable. 

16 17
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Vandalized Signs

(e) If the inspection guide panel blends with the sign and is

about the same brightness, the sign should be considered as

marginal and inspected again after a year.

Nighttime retroreflectivity can also be checked during the day by

using a highintensity spotlight. The spotlight can be flashed on

the sign face from inside a maintenance vehicle. If the sign flashes

back, its retroreflectivity is good. If there is no flashback, the sign’s

sheeting is dead and the sign should be replaced. The spotlight

should have a 200,000 to 400,000 candlepower bulb and be

powered through the vehicle’s cigarette lighter. The light and

observer should be between 100 and 200 feet from the sign.

Remember, night reviews are still important, while a sign may

appear adequate during the day, it may be non-visable at night.

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Vandalized Signs

A practical method is to use a series of retroreflective inspection

guide panels and a flashlight at night or during hours of relative

darkness. Agencies should assemble their own field repair kits, and

include all tools and materials, such as adhesive sheeting and

aluminum tape, that they need for common field repairs.

(a) Use masking tape or a spring clip to hold the appropriate

8”X 10” sign inspection guide panel to the clean area of

the sign face,

(b) Stand back about 30 feet from the sign, 

(c) Hold a flashlight about 2 inches from your eye and shine

it on the sign.

(d) If the inspection guide panel is brighter than the sign face

or the sign is illegible, the sign should be replaced.

18 19
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Missing Signs

Sign vandalism also includes the theft of signs. Missing signs can

be the result of storms or traffic incidents; however, the primary

reason in many areas is simply theft. While theft can’t be

eliminated it may be substantially reduced by making it difficult

to remove a sign and by developing and implementing laws to

penalize vandals.

Specific fasteners can be used to attach signs to support posts

which make it far more difficult for vandals to remove sign panels.

Among the more common special fasteners in use are:

• Expanding anchor bolts and blind

aluminum rivets.

• Bolts (or nuts) that require special tools to install and

remove them (such as fluted nuts or star bolts).

• Nuts with shearoff heads.

• Simply hammering down the excess portion of the threaded

bolt so that it cannot be easily unscrewed.

21

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Vegetation Clearing

These pictures of a local road were taken with in twenty feet of

each other and shows how easily the growth of vegitation can

block the visibility of a critical sign.

20
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Missing signs

Simple details of anti theft anti vandal fasteners

Shear off heads

Bent over bolts

23

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Missing Signs

Simple details of anti theft anti vandal fasteners

Expanding anchor and blind Aluminum Rivets

Fluted nuts (double pyramid shapes)

22

Nut

Neoprene or nylon washer

Carriage

bolt

Carriage bolt is hammered over

to prevent removal of nut

(Sign replacement requires

cutting off bolts)

1"

1"

1/2"

Typical

Pyramid

Nut

After installation back

nut is removed.

Neoprene

or nylon

washer

3/8"

Carriage

bolt

Neoprene

or nylon

washer

4" x 4" Wood post

Sign

Breakoff

groove 5/8" hex

Aluminum

expanding

rivets

U-channel

post

Sign

Neoprene or

nylon washer

No.1 No.2

Tufnuts

Junction

Neoprene

or nylon

washer

3/8"

Carriage

bolt Nylon

washer

4" x 4" Wood post

Sign
II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• General Procedures in the Repair and Maintenance of Signs

1. A record of all signs (in use and belonging to the agency)

should be maintained. Larger communities should maintain

a computer inventory of all signs and the essential

information about each sign. Smaller communities with a

limited number of signs (say 200 or less) should either

maintain a computer inventory or a file card inventory of

each sign in service. 

The essential information that should be maintained includes but

is not limited to:

• Type sign (i.e. R-1, STOP)

• Size of sign (i.e. 24” X 24”)

• Location (i.e. NW corner of 1 st and Barr and/or GPS

satellite location)

• Date of installation (or how long sign panel has been in use)

• Accident/maintenance history (i.e. each event of repair due

to accidents and maintenance activities, including 

changes made)

• Inspection dates (i.e. day/night or cleaning dates)

• Sign support type

• Any other signs mounted on the same support

25

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• Illegible and nonreflective signs

When a sign face becomes so

worn or faded that the message

is not legible or can be misread

during daytime or night, the

sign should be replaced. A sign

needs to be readable in ordinary

sunlight and still reflect enough

light at night to be a useful sign.

Nighttime visibility

Signs that may appear bright and clear during the day may lose their

retroreflective characteristics after long exposure to sunlight and/or

salt splashes. Nighttime retroreflectivity can be inspectedby using 

the criteria provided on page 18. Reviews should also focus on

identification and removal of non-standard signs, such as the one

below.

24
III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Location and Height of Signs

The location of signs is usually established by the guidance set

forth in the current edition of the “Manual on Uniform Traffic

Control Devices,” State standards and/or directives, and legal

procedures and/or requirements.

A sign may require replacement, an additional sign may be added

or a whole sign assembly (sign(s) and support) may require

replacement. Do not rely on original position and height of the

sign as appropriate criteria. It is important to check the location

of the support and the mounting height of the sign above the

roadway to ensure the sign is legible and crashworthy.

Additionally, it is essential to locate small sign supports

(crashworthy sign supports) so they function properly, and

remember, check new sign locations to ensure there are no utility

problems or sight obstructions. Before changing the location of a

support or the height of a sign, check with your supervisor.

The figures on next page show the recommended height and

location provided in the MUTCD.

27

II. REPAIR AND REPLACEMENT

OF SIGN PANELS

• General Procedures in the Repair and Maintenance of Signs

2. Each sign should have a unique inventory serial number

firmly attached or engraved on the back of the sign (this

helps in maintaining signs, relocating sign panels that are

found, and enforcing legal actions when stolen signs are

recovered).

3. Signs essential to driver, pedestrian and bicycle safety (such

as regulatory and warning) should be reviewed for visibility

and legibility annually, and as appropriate after severe wind

and snow storms (reviewers should be prepared to clean

signs that have salt and road oil build-up).

26
III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Positioning Signs

To obtain maximum reflection from traffic signs, yet eliminate

specular glare, signs should be correctly aligned. Specular glare is

the mirror type reflection characteristic of any glossy surface.

Under severe circumstances, such as direct sunlight, specular glare

can make the sign legend unreadable. Often this becomes

apparent from driver complaints.

• On straight sections of highway, sign should be positioned

slightly away from the driver. The recommended angle, as shown

below, is 93 degrees.

• On curved sections of highway, the sign should be positioned 

at an angle of 93 degrees away from the driver at the point where

the sign is to be read.

• On existing sign supports, signs can be shimmed or reattached

to reduce reflective glare.

29

III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Location and Height of Signs

The figures below represent the recommended height and location

as provided in the MUTCD.

*A height of 7’ or more from the bottom of the sign to the

ground is recommended in all areas where there are bus stops,

pedestrians or bicycle traffic.

28

Direction of Travel

Point at which sign

is to be read

*
III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Positioning Signs – Sign Turners

1. Pipe handle about four feet long.

2. Metal U-shape the size of the post.

Shown here is a locally fabricated tool for aligning the sign and

post before final tamping. A metal U-shape the size of the wood

post (4“X 4“ or 4“X 6“) has a pipe handle welded to it. After

attaching the sign to the post, filling the hole, and lightly tamping

the material, one person checks the sign to make certain it is

facing the roadway at the proper angle to be seen at night while

the other person rotates the post with the tool.

31

III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Positioning Signs

To obtain a 93 degree angle for roadside signs, the device

described below can be fabricated and used.

TO USE THIS DEVICE:

Position on the ground so that a line from Nail A to Nail B is

parallel to the driverís line of sight (either straight along the

roadway or where the driver should first see the sign). A string or

straight edge can then be placed from nails A to C to establish the

appropriate sign position.

30

3"

A

D C

B

E

F

U-channel Post

Pull

7"

A. 1 Pc. - 1 1/2” Black Pipe - 50” long

B. 1 Pc. - 5/8” x 3” x 10” long

C. 1 Pc. - 3/4” x 3/4” x 5/8” long

D. 1 Pc. - 1/4” x 3/4” x 20” long

E. 1 Pc. - 3/8” x 3/8” x 3” long

F. 1 - Clevis slip hook (remove eye)

PARALLEL TO DRIVERS 

LINE OF SIGHT

SIGN LOCATION

(POST LOCATION)

POSITION OF

SIGN FACE

NAIL B NAIL A

NAIL C

2

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III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Crashworthy Sign Support - U-Channel Steel Post

The U-channel, hot rolled steel post is the second most common

small sign support. It is considered breakaway since it will bend,

break or pull out of the ground when it is hit.

Post Support. The post should be driven into

the ground and not encased in concrete. Drive

posts into the ground no more than 3.5 feet to

make it easier to pull out damaged posts.

Breakaway Devices. Splices can be purchased

commercially to install at ground level (see

lower drawing). They allow the post to break

off on impact. These devices improve safety

when the post is hit, will make repair easier,

and will make it possible to use a U-channel

post when it has to be placed in a concrete area.

An alternate installation is to set a stub post in

the concrete with a 4-inch length available to

bolt to the sign post as a base connection.

Maximum Post Size

Max. Size Panel Post Size

18” X 24” 2 lb/ft

30” X 30” 3 lb/ft

36” X 48” 2 @ 2 lb/ft*

Sign Panels. Sign panels should be securely bolted to the post with

oversized washers. This will prevent the panel from separating

from the post on impact and then penetrating a windshield. Set

the bottom of the sign panel a minimum of 7 feet above the

pavement or ground. This limits the chance of the sign hitting a

car’s windshield.

* One post at each end of sign; not a single post made of two rails

bolted together

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III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Crashworthy Sign Supports - Wood Post

Small supports. Cross section

is 16 sq. inches. Posts should

be buried in firm ground.

Minimum recommended

depth is three feet. You may

need to bury deeper to

reduce vandalism. Do not

encase post in concrete. One

or two posts may be used.

Large Supports should be

drilled. A 6” X 8” wood post

can be used if the cross

section is weakened by

drilling two 3-inch holes as

shown in the lower drawing

(drill perpendicular to

roadway). A 4” X 4” is the

largest undrilled wood post

recommended to act as a

breakaway support.

Maximum Post Sizes

Max. Sign Panel Post Size

18” X 24” 4” X 4” nom.

30” X 30” 4” X 6” nom.(2” holes)

36” X 48” 6” X 6” nom.(2” holes)

Sign Panels. Sign panels should be bolted to the post with

oversized washers. This will prevent the panel from separating

from the post on impact and then penetrating a windshield. Set

the bottom of the sign panel a minimum of 7 feet above the

pavement or ground. This will limit the chance of the sign and

post rotating and hitting the car’s windshield.

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* For rural areas, the minimum height from

bottom of sign may be 5’.

*

*
III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Crashworthy Sign Supports — Slip Bases

When installing, replacing or repairing sign support systems

always follow the manufacturer’s instructions to ensure proper

performance.

In this case, the slip base supports are under several inches of back

fill, consequently failed to activate when hit, note the bending of

the left leg.

Typical torque requirements for slip base breakaway systems.

Post Size Slip Base Bolt Clamping Force Bolt Torque Max Torque

Pounds per Foot Diameter (in) (pounds) (inchpounds) (ftpounds)

1 - 8 1/2 920 - 1380 95 - 142 12

9 - 20 5/8 1740 - 2660 226 - 345 29

21 - 30 3/4 2400 - 3600 369 - 554 46

30 + 1 2400 - 3600 460 - 735 60

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III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Crashworthy Sign Supports - Square Steel Tube

Another sign post is the square steel tube (perforated) design. It is

used in many localities.

Post Support. Posts can be driven into

the ground. Do not place concrete

around the post. A broken or damaged

post is easier to remove if it is not

driven or set into the ground more

than three feet.

Breakaway Devices. Sleeve assemblies

like the one shown in the lower

drawing will increase the safety of a

sign when it is hit and make it easier

to repair. After the sign has been hit,

the broken stub of the post can be

removed from the base sleeve and a

new sign post put back in place.

Maximum Post Size

Max. Sign Panel Post Size

30 “ X 30” 2.25” X 2.25”

X 0.105”

Sign Panels. Attach the sign panels tightly to the post and use

oversized washers to keep the sign from breaking loose from the

post when a vehicle hits it. Sign panels should be mounted a

minimum of 7 feet above the pavement or ground.

There are many other products available commercially for sign

supports. Use depends on local requirements and costs. This

publication only shows four of the most common types of small

sign supports.

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III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Unsafe Practices

The environment can also be a factor on the safety characteristics

of sign supports. The two most common conditions that can

affect the crashworthiness of a sign support are erosion of soil at

the base and the growth of trees around the support.

Use of too many supports,

either on one sign or for a

group of signs can produce

a hazard. This supporting

system is too rigid and may

contribute to overturning,

loss of control or abrupt

stopping.

While the system used is a

break-away base the pedestal

it is mounted on was either

not back filled around or the

soil has eroded around it.

This support system is now a

hazard as it constitutes a rigid

concrete block more than

four inches above the

surrounding ground. This

can snag the under-carriage

of a vehicle causing it to stop

abruptly or go out of control.

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III. REPAIR AND REPLACEMENT OF SMALL

SIGN SUPPORTS

• Unsafe Practices

Some practices or efforts to improve maintenance can reduce the

positive safety aspects of crashworthy sign and sign support

designs. The following examples will give you an idea of the kind

of things to watch out for. Look carefully around your own areas

of responsibility to ensure that past efforts have not compromised

the crashworthiness of the design or situation.

This sign has multiple posts

supporting it when two are

probably enough. Also, two

horizontal braces cross the

bottom. These increase the

strength of the support greatly,

but a small car hitting this is

likely to stop suddenly, causing

a severe accident. Larger posts

with breakaway mechanisms at

the ground are better.

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V. MATERIALS AND EQUIPMENT USED IN

MAINTAINING SIGNS

Sign Posts

For routine patrols, take several sign posts commonly used in your

patrol area. Remember there may be several types in common use

in the area including wood, steel U-channel, perforated square

tube, etc. Suggested numbers of posts for large areas include:

1. Wood post 4” X 4” X 12’ - say 6

2. Wood post 4” X 6” X 14’- pre-drilled say 4

3. Wood post 4” X 6” X 16’ - pre-drilled say 4

4. U-channel 8’ long - say 4

5. U-channel 10’ long - say 4

6. Square steel tube 2.25” X 2.25” X 10 - say 4

7. Others as unique to your area

Supplies and Sign Hardware Items

You should take enough hardware to replace a minimum of 20

sign panels and 10 sign supports. When your hardware supply

falls below this level, obtain more before beginning a patrol. You

will also need to carry a supply of :

1. Anti-theft, vandal-resistant fasteners.

2. Oversized neoprene or nylon washers.

3. Several boxes of bolts with nuts.

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IV. CLEANING AND CHECKING SIGNS AND

SIGN SUPPORTS

Signs are very important to motorist, bicyclist and pedestrian

safety, particularly regulatory and warning signs. These signs can

fade, be painted over, get knocked down, be stolen, be blocked

from view because of vegetation or man-made features, cease to

apply to the current situation, or be dirty. Occasionally, someone

may even add signs that are not appropriate or consistent with the

control of traffic or driver’s needs. Checking the existing signs

against sign inventory can identify any discrepancies and resolve

those discrepancies before they contribute to an accident.

Signs should be checked at least twice a year as conditions dictate.

Desirable times are after winter and before the start of the school

year. (This cycle provides for identifying winter damage and

blocked visibility as a result of new vegetation growth.) As

previously mentioned, special reviews should be conducted after

bad storms when drifting snow blocks visibility or trees are blown

down.

During sign checks it is also desirable to clean dirty signs and

refurbish faded or damaged signs. The inspectors should keep a

record of all actions taken and recommended. These records

should be added to the sign inventory.

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V. MATERIALS AND EQUIPMENT USED IN

MAINTAINING SIGNS

Handtools

Suggested handtools for sign maintenance patrols:

1. Several different size adjustable wrenches and a pair of

adjustable (horse-faced) pliers.

2. Weed cutter for clearing vegetation blocking signs.

3. Loopers for clearing vegetation.

4. 3-cu. ft. utility wheelbarrow as there may be a need to mix

concrete for sign bases, move hole spoil, or bring in

material to fill holes.

5. Brace and bits to drill holes in wood posts.

6. Set of woodworking chisels for trimming wood posts.

7. Hacksaw to cut bolts and rivets.

8. Crosscut saw for cutting wood posts.

9. Post hole auger, post hole digger, and post hole breaker bar

for preparing new post holes and resetting posts.

10. Doublehanded slip hammer of suitable size for driving

posts, usually U-channel and square tube.

11. 16-lb. or 20-1b. double-faced sledge hammer.

12. 6-lb. double-faced hammer.

13. 16-oz. or 20-oz. curved claw hammer.

14. Long-handled shovel.

15. Heavy-duty tall step ladder or an extension ladder.

16. Rubber mallet.

17. Fender dolley.

18. Cold chisels, various sizes.

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V. MATERIALS AND EQUIPMENT USED IN

MAINTAINING SIGNS

If you plan to make field repairs to damaged sign faces (repair the

legend or lettering) rather than do this in the shop, you will need

additional field supplies, including:

Materials

1. Face mask to protect lungs from spray paint and dust.

2. One package of assorted capital letters.

3. One package of assorted arrows and numbers.

4. Two rolls of transparent film (one 2 inch width, one 3 inch

width).

5. Four one quart cans of clean sealer or equal.

6. Four one quart cans of thinner or equal.

7. One pint can of activator or equal.

8. One roll each of reflective tape in red, yellow, green,

orange, blue and white (background).

9. One container of naphtha, and a large can of wood filler.

10. Two rolls of aluminum foil tape for backing sign holes.

11. Utility knife.

12. Two rolls of masking tape.

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VI. TRAFFIC CONTROL DURING SIGN

MAINTENANCE

Shoulder Work with Minor Encroachment

Guidance:

1. All lanes should be a minimum of 3 m (10 ft) in width as 

measured to the near face of the channelizing devices. 

2. The treatment shown should be used on a minor road 

having low speeds. For higher-speed traffic conditions, a

lane closure should be used.

Option:

3. For short-term use on low-volume, low-speed roadways

with motor vehicle traffic that does not include longer and 

wider heavy commercial vehicles, a minimum lane width of

2.7 m (9 ft) may be used.

4. Where the opposite shoulder is suitable for carrying motor 

vehicle traffic and of adequate width, lanes may be shifted 

by the use of closely-spaced channelizing devices, provided 

that the minimum lane width of 3 m (10 ft) is maintained.

5. Additional advance warning may be appropriate, such as a 

ROAD NARROWS sign.

6. Temporary traffic barriers may be used along the work space.

7. The shadow vehicle may be omitted if a taper and 

channelizing devices are used.

8. A truck-mounted attenuator may be used on the shadow 

vehicle.

9. For short-duration work, the taper and channelizing devices 

may be omitted if a shadow vehicle with activated rotating 

lights or strobe lights is used.

Standard:

10. Although vehicle hazard warning signals can be used to 

supplement the rotating lights or strobe lights, they shall 

not be used instead of rotating lights or strobe lights.

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VI. TRAFFIC CONTROL DURING SIGN

MAINTENANCE

Shoulder Work with Minor Encroachment
VI. TRAFFIC CONTROL DURING SIGN

MAINTENANCE

Lane Closure on Two-Lane Road Using Flaggers

Option:

1. For low-volume situations with short work zones on straight roadways 

where the flagger is visible to road users approaching from both 

directions, a single flagger, positioned to be visible to road users 

approaching from both directions, may be used (see Chapter 6E).

2. The ROAD WORK AHEAD and the END ROAD WORK signs may 

be omitted for short-duration operations.

3. Flashing warning lights and/or flags may be used to call attention to the 

advance warning signs. A BE PREPARED TO STOP sign may be added

to the sign series.

4. a flagger or a law enforcement officer may be used at the highway-rail 

grade crossing to minimize the probability that vehicles are stopped 

within 4.5 m (15 ft) of the highway-rail grade crossing, measured from 

both sides of the outside rails.

Guidance:

5. Channelizing devices should be extended to a point where they are 

visible to approaching road users.

6. Floodlights should be provided as needed to mark flagger stations 

at night.

7. When used the BE PREPARED TO STOP sign should be located between

the Advance Flagger sign and the ONE LANE ROAD sign.

8. When a highway-rail grade crossing exists within or upstream of the 

transition area and it is anticipated that backups resulting from the lane 

closure might extend through the highway-rail grade crossing, the 

temporary traffic control zone should be extended so that the transition 

area preceeds the highway-rail grade crossing.

9. When a highway-rail grade crossing equipped with active warning devices 

exists within the activity area, provisions should be made for keeping 

flaggers informed as to the activation status of these warning devices.

10. When a highway-rail grade crossing exists within the activity area, drivers 

operating on the left side of the normal centerline should be provided with 

comparable warning devices as for drivers operating on the right side of the 

normal centerline.

11. Early coordination with the railroad company should occur before 

work starts.

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VI. TRAFFIC CONTROL DURING SIGN

MAINTENANCE

Lane Closure on Two-Lane Road Using Flaggers

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VI. TRAFFIC CONTROL DURING SIGN

MAINTENANCE

Lane Closure on Low -Volume Two-Lane Road 

VI. TRAFFIC CONTROL DURING SIGN

MAINTENANCE

Lane Closure on Low -Volume Two-Lane Road 

Option:

1. This temporary traffic control zone application may be 

used as an alternate temporary traffic controlplan to the 

lane closure with flaggers (Figure 6H-10), when the 

following conditions exist:

a. Motor vehicle traffic volume is such that sufficient gaps

exist for motor vehicle traffic that must yield.

b. Drivers from both directions are able to see 

approaching motor vehicle traffic through and beyond the

work site.

Standard:

2. When flaggers are used, the Flagger symbol sign shalll 

be used in place of the YIELD AHEAD sign.

Option:

3. The type B flashing warning lights may be placed on the 

ROAD WORK AHEAD and the ONE LANE ROAD 

AHEAD signs whenever a night lane closure is neccessary.
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VII. SIGN MAINTENANCE RECORDS

Maintenance Records

Keeping records of sign maintenance and inspections is

important, particularly small signs as these are the ones most often

affected by weather and vehicular accidents. Keeping good records

will help you:

• Make good decisions about when old sign panels

should be replaced,

• Respond more quickly to relocating or replacing signs

frequently damaged,

• Determine which materials are best suited for your area and

need to effectively manage your sign program,

• Work with law enforcement personnel to reduce vandalism,

and

• Defend against lawsuits arising from collision with or

challenges about the condition of the sign.

The three main elements of maintenance records include:

• The sign inventory,

• The log or record of incident reports, and

• The sign/sign support maintenance records.

VII. SIGN MAINTENANCE RECORDS

Sign Inventory

It is very important to develop and maintain a sign inventory.

Without a record of the type, size, location, and age of a sign, it is

often difficult to know what signs are missing or where

maintenance efforts can be best applied. A sign inventory can help

you respond quickly and more effectively to an incident report. It

can help identify areas where there are vandalism or accident

problems. Depending on the size of the community and the

equipment available, a sign inventory can be developed on ledger

books, file cards, microcomputers or mainframe computers. As

long as the people using it know how it works and maintain

current information on it, it can be effective. Information that

should be included in the inventory includes:

• Sign location including street or highway, milepost or block

location, and the traffic direction it faces.

• Sign type or name (i.e. STOP, NO PASSING, etc.).

• Sign panel size ( shape) (i.e. 18”X 18”, 30”X 30” ).

• Date installed or replaced.

• Date of any changes and a brief note of what the change 

was (i.e. raised it 2 feet, changed pipe post to 4” by 4”

wood post, etc.).

• Date of most recent inspection or repair.

Small communities with less than one-hundred to one-hundred

and fifty signs may choose to use simple three by five inch cards

to maintain information on each sign. Larger inventories of signs

can be managed on computer systems available by both sign

vendors and through local Technical Assitance Programs.
VII. SIGN MAINTENANCE RECORDS

Maintenance Records

Maintenance records should be kept for any new installations,

repairs of existing installations, or replacement jobs done on signs

and sign supports. This will help to determine changes in your

maintenance activities that improved driver and work safety,

reduced costs, and reduced potential for liability law suits. A sign

(and sign support) maintenance record, report, file, or log should

include, as a minimum, the following information:

• Time and date of work and name of person responsible for

completed work.

• Sign/support location by street or highway and traffic

direction it is facing.

• Type of sign and size of sign if replaced

• Type and size of support if replaced.

• If the following were/are to be checked what were they?

* Height to bottom of sign

* Color of sign

* Size of sign

*Any breakaway features of post

* Orientation of sign (for night traffic)

* Wear or fading of sign

* Location with respect to pavement

* Anything blocking driverís view of sign

Signs that need maintenance frequently should be investigated.

If they are being repeatedly stolen. Then vandal proof hardware

should be used. If they are being hit by cars. Then the traffic

engineer should be notified that there may be something about

the streets design or the condition of the pavement that is

causing problems.

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VII. SIGN MAINTENANCE RECORDS

Incident reports

Incident reports should include:

• The date and time the report is made or received,

• Who made the report and who received and entered the

report,

• A brief description of the problem reported or observed, and

• what action was taken, when it was taken and who was

responsible for it. If there was a subsequent review of the

work then note who made the review, when it was made and

any subsequent actions required and taken.

This type report could read as follows: “The STOP sign (inv.

#3412) on the Northwest corner of the intersection of Oak St.

and Elm St. was reported bent by a concerned citizen. The sign

was checked and straightened by J. Smith on January 16, 2000.”

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VII. RESOURCE MATERIAL

Resources available for Improving the maintenance

of signs and sign supports for local roads and streets:

• The Manual of Uniform Traffic Control Devices is the 

resource document that provides the standards for the size,

shape, color, message, appropriate use and location for 

signs. The current manual is available on the Internet 

through the web site addressed: 

http://mutcd.fhwa.dot.gov

• Information crash tested sign supports is available from 

State’s Local Technology Assistance Program. It is also 

available on the Internet through the web site addressed:

http://safety.fhwa.dot.gov/fourthlevel/hardware/

signsuppt.html

• Information on State Local Technology Assistance 

Programs is available on the Internet through web site. 

Contact your local State University for information on 

technology sharing.

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