US.Deporlmenl 

of Transportation 

1200 New Jersey Ave., SE 

Washington. D.C. 20590 

Federal Highway 

Administration May 12. 20 16 

In Reply Refer To: 

H SST-1 / WZ-335 

Mr. Felipe Almanza 

Tra!Fix Devices Inc. 

I60 Avcn ida La Pala 

San Clemente, California 92673 

Dear Mr. Almanza: 

This lellcr is in response to your February -1 . 20 I 4 request for the Federal Highway 

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

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

assigned f.'I IWA control number \VZ-335 and is valid until a subsequent letter is issued by 

Fl l\VA that expressly references 1his device. 

Decision 

The following devices are eligible, with details provided in the fom1 which is attached as an 

integral pnrt of this letter: 

•Aluminum Buster Sign Stand 

Scope of Ch is Letter 

To be found eligible for Federal-aid funding. new roadside safety dc,·ices should meet the crnsh 

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

Transportation Officials· Manual for Assessing Safety Hardware (MASH). However. the 

FHWA, the Department of Transportation, and the United States Government do not regulnte the 

manufacture of roadside safety devices. Eligibil ity for reimbursement under the Federal-aid 

highway program does not establish approval. certification or endorsement ofthe device for any 

particular purpose or use. 

This letter is not a determinalion by the Fl IWA, the Department ofTransportation, or the United 

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

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

manufacturing, installation, and maintenance arc required in order for this device lo function as 

tested. 

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

structural lcatures. nor conformity with the Manual on Uni fo rm Traffic Control Devices. 
2 

Eligibility for Reimbursement 

Based solely on a review ofcrash 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 ofthe American Association of State Highway and Transportation 

Officials' Manual for Assessing Safety Hardware {MASH). Therefore, the device is eligible for 

reimbursement under the Federal-aid highway program if installed under the range oftested 

conditions. 

Name ofsystem: Aluminum Buster Sign Stand 


Type of system: Work Zone Traffic Control Device 


Test Level: MASH Test Level 3 


Testing conducted by: KARCO Engineering, Inc. 


Date of.request: February 4, 2014 


Date initially acknowledged: July 3, 2014 


Date of completed package: February 23, 2016 


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

stated within the attached form. 

Full Description of the Eligible Device 

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

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

form. 

Notice 

1fa manufacturer makes any modification to any oftheir roadside safety hardware that has an 

existing eligibility letter from FHWA, the manufacturer must notify FHWA ofsuch modification 

with a request for continued eligibility for reimbursement. The notice ofall modifications to a 

device must be accompanied by: 

o 	 Significant modifications - For these modifications, crash test results must be 

submitted with accompanying documentation and videos. 

o 	 Non-signification modifications - For these modifications, a statement from the 

crash test laboratory on the potential effect ofthe modification on the ability of 

the device to meet the relevant crash test criteria. 

FHWA's detennination ofcontinued eligibility for the modified hardware will be based on 

whether the modified hardware will continue to meet the relevant crash test criteria. 

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 ofthe MASH. 
3 

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

privilege. This letter is based on the premise that infomrntion and reports submitted by 

you are accurate and correct. We reserve the right lo modify or revoke this letter if: (1) 

there arc any inaccuracies in the information submiltcd in support of your request for this 

letter: (2) the qualification testing was 1la\\'ed, (3) in-service perfom1ancc 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 v·:as 

issued in error or otherwise does nol reflect full and complete in formation about the 

crnshworthiness of the system. 

Standard Provisions 

• 	 To prevent misunderstanding by others, this letter ofeligibility designated as Fl IWA 

control number WZ-335 shall not be reproduced except in full. This letter and the test 

documentation upon which it is based are public infonnation. All such leucrs and 

documentation may be reviewed upon request. 

• 	 This letter sha ll not be construed as authorization or consent by the FHW/\to use, 

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

• 	 If the subject device is a patented product it may be considered lo be proprietary. If 

proprietary systems are specified by a highway agency for use on Federal-aid projects: 

(a) they must be supplied through competiti ve bidding wi th equall y suitable unpalented 

it s~ (b) the highway agency must certify that they arc essential for synchronization 

with the existing highway facilities or that no equally suitable alternative exists; or (c) 

they must be used for research or for a distinctive type or construction on relatively short 

sections of road for cxperimenlal purposes. Our regulations concerning proprietary 

products are contained in Title 23, Code of Federal Regulations, Section 635.4 11. 

Sincerely yours. 

Michael S. Griffith 

Director. Office of Safety Technologies 

Office of Safety 

Enclosures 
 Version 9.1 (11/15) 

Page 1 of 4 

Request for Federal Aid Reimbursement Eligibility

of Highway Safety Hardware 

 Date of Request: February 2014 New Resubmission 

ter

Name: Felipe Almanza 

Company: TrafFix Devices Inc. 

Submit

Address: 160 Avenida La Pata, San Clemente, California 92673 

Country: USA

Michael S. Griffith, Director To: FHWA, Office of Safety Technologies 

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

highway program. 

! - ! - ! 

System Type Submission Type Device Name / Variant Testing Criterion Test 

Level 

'WZ': Crash Worthy Work 

Zone Traffic Control Devices 

Physical Crash Testing 

Engineering Analysis

 Aluminum Buster 

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. 

Identification of the individual or organization responsible for the product: 

Contact Name: Felipe Almanza Same as Submitter 

Company Name: TrafFix Devices Inc. Same as Submitter 

Address: 160 Avenida La Pata, San Clemente, California 92673 Same as Submitter 

Country: U.S.A Same as Submitter 

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. Corporate Office160 Avenida La Pata, San Clemente, CA 92672 and Karco Engineering LLC 

9270 Holly Road, Adelanto, CA 92301 share no ($0.00) financial interests between the two organizations. 

This includes no ($0.00) shared financial interest but not limited to: 

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

values are not needed); 

ii. Consulting relationships 

iii. Research funding or other forms of research support; 

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

v. Licenses or contractual relationships; or 

vi. Business ownership and investment interests. 
 Version 9.1 (11/15) 

Page 2 of 4 

PRODUCT DESCRIPTION 

New Hardware or 

Significant Modification 

Modification to 

Existing Hardware 

The TrafFix Devices Aluminum Buster is a work-zone traffic control device consisting of four major assemblies, 

one spring base assembly, an aluminum vertical mast (inner and outer), four aluminum legs, and one vinyl roll 

up sign. 

The steel spring base assembly is the platform for bolting the mast, legs, and springs in the final assembly. 

Bolted to the steel base are two vertically aligned coil springs. The coil springs have a diameter of 2.5" (64 mm) 

and are 6.5" (165 mm) in height. The telescoping vertical aluminum mast assembly consists of an inner and 

outer mast. The outer mast is 1.25" (32 mm) X 1.25" (32 mm) X 0.1" (2.54 mm) wall and is bolted directly to the 

springs. The roll up sign is attached to the telescoping inner mast by means of a clamp on roll up sign bracket. 

The sign can be raised and lowered to the desired height. The roll up vinyl sign measures 4.0 ' (1.2 m) X 4.0' (1.2 

m). 

The sign stand is supported by four aluminum legs with overall dimensions of 42.2" (1072 mm) X 1" (25.4 mm) X 

1" (25.4 mm) X 0.1" (2.54) wall. The legs are stored in a vertical position and when they are deployed, the legs 

drop to the surface creating an X-footprint. The X-footprint measures 6.6' (2.0 m) X 3.3' (1.0 m). Sandbags can 

be placed on the legs as needed for ballast. 

CRASH TESTING 

A brief description of each crash test and its result: 

Required Test 

Number 

Narrative 

Description Evaluation Results 

3-70 (1100C) 

Designed to evaluate the ability of a small vehicle to activate 

any breakaway, fracture, or yielding mechanism. Is 

considered optional for work-zone traffic control devices 

weighting less than 220lb (100kg). 

Non-Critical, not conducted 

3-71 (1100C) 

A 2,430 lb (1102 kg) small car approaching the test article at 

impact speed of 62.4 mph (100.42 km/h) with a critical impact 

angle between 0° and 90°. For this test, two Aluminum Buster 

Sign Stands were impacted. The first article was aligned at 90° 

and the second article was aligned to 0° to the test vehicle's 

direction of travel. 

Upon impact the Aluminum Buster's vertical mast yielded and 

fractured from the spring base assembly in a predictable 

manner in both the 90° and 0° positions. 

The test vehicle’s occupant compartment was not penetrated 

by the test articles. The windshield was impacted by the signs 

and deformed 0.9” (22 mm). Debris from the test articles did 

not cause a hazard to the driver’s vision. The vehicle 

remained upright and did not exceed 75° roll angle through 

the test. The vehicle did not leave its lane and its trajectory 

was stable after both sign stands were impacted. 

PASS 
 Version 9.1 (11/15) 

Page 3 of 4 

Required Test 

Number 

Narrative 

Description Evaluation Results 

3-72 (2270P) 

A 4,970.3 lb (2,254.5 kg) pickup truck approaching the test 

article at nominal speed of 63.57 mph (102.3 km/h) with a 

critical impact angle between 0° and 90°. For this test two 

Aluminum Buster Sign Stands were impacted. The first article 

was aligned at 90° and the second article was aligned to 0° to 

the test vehicle's direction of travel. 

Upon impact the Aluminum Buster's vertical mast yielded and 

fractured from the spring base assembly in a predictable 

manner in both the 90° and 0° positions. 

The test vehicle’s occupant compartment was not penetrated 

by the test articles. The windshield was impact by the signs 

and deformed 1.5” (38 mm). Debris from the test articles did 

not cause a hazard to the driver’s vision. The vehicle 

remained upright and did not exceed 75° roll angle through 

the test. The vehicle did not leave its lane and its trajectory 

was stable after both sign stands were impacted. 

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.): 

Laboratory Name: KARCO Engineering, INC 

Laboratory Signature: Steven Matsusaka Digitally signed by Steven Matsusaka 

DN: cn=Steven Matsusaka, o=KARCO Engineering, LLC., ou, 

email=smatsusaka@karco.com, c=US 

Date: 2016.02.22 17:28:22 -08'00' 

Address: 9270 Holly Road, Adelanto, Ca. 92301 Same as Submitter 

Country: United States of America Same as Submitter 

Accreditation Certificate 

Number and Dates of current 

Accreditation period : 

TL-371, December 18, 2015 

Digitally signed by Felipe Almanza 

DN: cn=Felipe Almanza, o=TrafFix Devices 

Inc., ou=Felipe Almanza, 

email=falmanza@traffixdevices.com, c=US 

Date: 2016.02.23 11:54:41 -08'00' 

Submitter Signature*: 

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. 
 Version 9.1 (11/15) 

Page 4 of 4 

FHWA Official Business Only: 

Eligibility Letter AASHTO TF13 

Number Date Designator Key Words 

WZ-335 May 12, 2016 Work Zone, Sign Support 
D 

C 

B 

A 

8 7 6 5 4 3 2 1 

54in 

[1.37m] 

FROM GROUND LEVEL 

TO BOTTOM OF SIGN 

40in 

[1.02m] 

48in 

1.22m

 SQUARE SIGN 

SIGN SUBSTRATE 

80in 

[2.03m] 

91in 

[2.31m] 

APPROX. 120.29in 

3.06m 

ROLL-UP BRACKET 

ALUMINUM BUSTER SIGN STAND 

OVERALL WEIGHT: APPROX. 29 LBS [13.15kg] (NO SIGN)

OVERALL DIMENSIONS: APPROX. 40"[1.02m] X 80"[2.03m] X 91"[2.31m]

FRAME MATERIAL: ALUMINUM TUBING 

ALUMINUM TUBING 

REVISIONS 

REV. DESCRIPTION DATE APPROVED 

A INITIAL RELEASE 12/23/2013 JS 

D 

C 

B 

A 

8 7 6 5 4 3 2 1 

APPROVED BY: 

TITLE: 

SIZE

B 

DWG. NO. REV 

A 

SHEET 1 OF 1 

CHECKED BY: 500-170

DRAWN BY: DATE: 

DATE: 

DATE: 

UNLESS OTHERWISE SPECIFIED: 

ALL DIMENSIONS ARE IN INCHES[mm].

TOLERANCES: 

FRACTIONAL: X/X 1/16" [1.6mm]

DECIMAL: X.X .0625"

 X.XX .032"

 X.XXX .015" 

DEGREES: 0.5 

JEREMY SMITH 12/23/13

FA 12/23/13 

FA 12/23/13

ALUMINUM BUSTER 
SECTION 4 


MASH TEST 3-71 SUMMARY 

Test Article: TrafFix Devices Aluminum Buster Project No. P33186-01 

Test Program: MASH 3-71 Test Date: 12/30/13 

SEQUENTIAL PHOTOGRAPHS 


0.000 s 0.200 s 0.400 s 0.600 s 0.800 s 

PLAN VIEW 

110 m 105 m 100 m 95 m 90 m 85 m 80 m 75 m 70 m 65m 35m 30m 25m 20 m 15 m 

1.000 s 

10m 5m Om -5m -10m 

Pre-Test 

• Artlcle 1 

• Article 2 

• Vehlele 


Post-Test 


• Debris 


• Vahlcla 


• 

• • • •• • • . (JD) 

• • • 

8 TR-P33186-01-A 

SECTION 4 

MASH TEST 3-71 SUMMARY ... (CONTINUED) 

Test Article: TrafFix Devices Aluminum Buster Project No. P33186-01 

Test Program: MASH 3-71 Test Date: 12/30/13 

SUMMARY TABLE 

GENERAL INFORMATION IMPACT CONDITIONS 

TEST AGENCY KARCO Engineering, LLC. IMPACT VELOCITY (ARTICLE 1) 62.40 mph (100.42 km/h) 

TEST NUMBER P33186-01 EXIT VELOCITY (ARTICLE 1) 60.57 mph (97.47 km/h) 

TEST DESIGNATION 3-71 IMPACT ANGLE (ARTICLE 1) 90.0 

TEST DATE 12/30/13 IMPACT VELOCITY (ARTICLE 2) 60.49 mph (97.35 km/h) 

TEST ARTICLE EXIT VELOCITY (ARTICLE 2) 58.63 mph (94.36 km/h) 

TEST ARTICLE NAME I MODEL Aluminum Buster IMPACT ANGLE (ARTICLE 2) 0.0 

TEST ARTICLE TYPE Work-Zone Traffic Control Device IMPACT LOCATION Center of Mast 

SIGN PANEL HEIGHT 5.7ft.(1.7m) VEHICLE STABILITY Satisfactory 

SIGN PANEL WIDTH 5.7ft. (1.7 m) OCCUPANT RISK VALUES 

MOUNTING HEIGHT OF SIGN PANEL 7.5 ft. (2.3 m) OCCUPANT IMPACT 

VELOCITY 

Longitudinal 1 

1 

1 

1 

TOTAL ARTICLE WEIGHT 34.0 lbs (15.4 kg) Lateral 

TEST VEHICLE RIDEDOWN 

ACCELERATION (g's) 

Longitudinal 

VEHICLE TYPE I DESIGNATION 1100C Lateral 

YEAR, MAKE AND MODEL 2009 Kia Rio VEHICLE DAMAGE 

CURB MASS 2,494.5 lbs (1,131.5 kg) VEHICLE DAMAGE SCALE 12-FD-1 

TEST INERTIAL MASS 2,430.6 lbs (1,102.5 kg) COLLISION DAMAGE CLASSIFICATION 12FDEW1 

GROSS STATIC MASS 2,595.9 lbs (1 , 177.5 kg) MAXIMUM DEFORMATION 0.9 in. on the vehicle windshield 

1

Values not calculated due to test article weight being less than 220 lbs (100 kg) 

9 TR-P33186-01-A 

SECTION 4 


MASH TEST 3-72 SUMMARY 


Test Article: Aluminum Buster Project No. P33050-01 

Test Program: MASH 3-72 Test Date: 12/30/13 

SEQUENTIAL PHOTOGRAPHS 


0.000 s 0.200 s 0.400 s 0.600 s 

PLAN VIEW 

I 

•' _..... '. • t <t ... ...., •, .. ,~·!! 

.. 

0.800 s 1.000 s 

95 m 90 m 85 m 80 m 75 m 70 m 65 m 60 m 55 m 50 m 45 m 40 m 35 m 30 m 25 m 20 m 15 m 10 m 5 m Om -5 m -1 O m 

0 

0 

0 

Pre-Test Post-Test 

• Vehicle • Vehicle 

• Article 1 • Article 1 

• Article 2 • Article 2 

8 TR-P33050-01-A 

Test Article: 

Test Program: 

SECTION 4 

MASH TEST 3-72 SUMMARY ... (CONTINUED) 

Aluminum Buster 

MASH 3-72 

Project No. 

Test Date: 

P33050-01 

12/30/13 

SUMMARY TABLE 

GENERAL INFORMATION IMPACT CONDITIONS 

TEST AGENCY KARCO Engineering, LLC. IMPACT VELOCITY (ARTICLE 1) 63.57 mph (102.31 km/h} 

TEST NUMBER P33050-01 EXIT VELOCITY (ARTICLE 1) 62.84 mph (101.13 km/h) 

TEST DESIGNATION 3-72 IMPACT ANGLE (ARTICLE 1) 90.0 

TEST DATE 12/30/13 IMPACT VELOCITY (ARTICLE 2) 61.25 mph (98.57 km/h) 

TEST ARTICLE EXIT VELOCITY (ARTICLE 2) 60.76 mph (97.78 km/h) 

TEST ARTICLE NAME I MODEL Aluminum Buster IMPACT ANGLE (ARTICLE 2} 0.0 

TEST ARTICLE TYPE Work-Zone Traffic Control Device IMPACT LOCATION Center of Support Post 

SIGN PANEL HEIGHT 5. 7 feet (1.7 meters) VEHICLE STABILITY Satisfactory 

SIGN PANEL WIDTH 5.7 feet (1 .7 meters) OCCUPANT RISK VALUES 

MOUNTING HEIGHT OF SIGN PANEL 7.6 feet (2.3 meters) OCCUPANT IMPACT 

VELOCITY 

Longitudinal 1 

1 

1 

1 

TOTAL ARTICLE HEIGHT 10.0 feet (3.1 meters) Lateral 

TEST VEHICLE RIDEDOWN 

ACCELERATION (g's) 

Longitudinal 

VEHICLE TYPE I DESIGNATION 2270P Lateral 

YEAR, MAKE AND MODEL 2008 Dodge Ram VEHICLE DAMAGE 

CURB MASS 4,860.1 lbs (2,204.5 kg) VEHICLE DAMAGE SCALE 12-FD-1 

TEST INERTIAL MASS 4,970.3 lbs (2,254.5 kg) COLLISION DAMAGE CLASSIFICATION 12FDEW1 

GROSS STATIC MASS 4,970.3 lbs (2,254.5 kg) MAXIMUM DEFORMATION 1.5 in. on the windshield 

1

Values not calculated due to test article weight being less than 220 lbs (100 kg) 

9 TR-P33050-01-A 

TrafFix Devices, Inc. 

160 Avenida La Pata 

San Clemente, CA 92673 

Attention: Mr. Felipe Almanza 

Date: January 12, 2016 

Mr. Felipe Almanza, 

On December 30, 2013 two test level 3, (tests 71 and 72) were conducted on the TrafFix 

Devices Aluminum Buster Sign Support based on the Manual for Assessing Safety Hardware 

(MASH) test procedure. The as-tested test article weight was 34.0 lbs (15.4 kg) . Based on the 

requirements outlined in the MASH test procedure, test 3-70 is considered optional for test 

articles weighing less than 220 lbs (100 kg). Because the total weight of the TrafFix Devices 

Aluminum Buster Sign Support was less than 220 lbs (100 kg), test 3-70 was not conducted. 

For the test level 3 (test 71) on the Aluminum Buster Sign Support the test vehicle's hood height 

dimension measurement was 31 .1 in. (790 mm). The specified hood height dimension 

measurement as outlined in the MASH test procedure is 24.0 in. +/- 4 in. (61 O mm +/- 102 mm). 

We determined that the use of this vehicle was acceptable and the differences in the hood 

height can be attributed to the changing vehicle fleet and the different methods used to take the 

hood height measurement. Furthermore, we felt that the difference in the hood height posed no 

significant effect on the performance of the test article. 

Sincerely yours, 

f)e/~ Frank D. Richardson 

President 

KARCO Engineering, LLC. 

Tel: (760) 246-1672 

Fax: (760) 246-8112 

KARCO Engineering, LLC . 

9270 Holly Road , Adelanto, CA 92301 

info@karco.com 

www.karco.com 
TrafFix Devices, Inc. 

160 Avenida La Pata 

San Clemente, CA 92673 

Attention: Mr. Felipe Almanza 

Date: April 20, 2016 

Mr. Felipe Almanza, 

On December 30, 2013, one Test Level 3, Test 71 was conducted on the TrafFix Devices, Inc. 

Aluminum Buster per the Manual for Assessing Safety Hardware (MASH) test procedure. The 

test vehicle used for this test was a 2009 Kia Rio 4-door sedan. The test vehicle had a hood 

height of 31.1 in. (791 mm). The specified hood height dimension measurement as outlined in 

the MASH test procedure is 24.0 in. ± 4 in. (600 mm ± 100 mm). In recent years, the Kia Rio 

test vehicle’s hood height has been increasing with its model year. An Interlaboratory 

Comparison performed at Task Force 13 has confirmed this observation. 

Despite the hood height dimension falling out of the MASH tolerance, KARCO determined that 

the dimension would not have a significant effect on the performance of the device for this test. 

The Aluminum Buster is designed to breakaway near its base in the event of an impact in order 

to prevent severe impacts to the test vehicle’s windshield and to avoid potentially blocking the 

driver’s vision. For this test, the test vehicle’s bumper makes first contact with the sign mast. 

The breakaway is activated upon impact with the bumper, before the hood height can affect the 

impact dynamics. Thus, a variation in the hood height would not affect the results of this test. 

Sincerely yours, 

Steven D. Matsusaka 

Engineering Department Supervisor 

KARCO Engineering, LLC.