812 - PERMANENT SIGNING
800-39 b. Shop Fabrication of Signing Items.
1.Flat Sheet Signs. Prov ide flat sheet sign blanks that comply with the Contract Documents. Remove warps, burrs and other defects.
2.Reinforced Panels. Provide reinforced panels of either extrusheet or extrud ed fabrication that comply with the Contract Documents and these requirements: Cut the ends of all panels at 90º angles to within ⅛ inch of the length shown in the Contract Documents. If the panel is extrusheet fabrication, do not exceed a 1/32 inch mismatch between the edge of the sheet and the extrusion it is fastened to. Remove warps, burrs and other defects.
3.Flat Sheet Sign Blank and Reinforced Panel Preparations. After fabrication, prepare the metal for sheeting application using a Class 2 conversion coating according to ASTM B 921, "Standard Specification for Non- hexavalent Chromium Conversion Coatings on Aluminum and Aluminum Alloys". Handle the metal with a mechani cal device or clean canvas gloves, between the etching operation and application of retroreflective sheetin g. Prevent the metal from coming in contact with greases, oils or other contaminants before the application of sheeting, films or inks.
4.Application of Retroreflective Sheeting. Use either heat activated or pressure sensitive retroreflective sheeting of the color shown in the Contract Documents. Apply the sheeting to the treated blanks and panels according to the manufacturer’s recommendation, or by a method that will produce an equivalent result. During fabrication of sign faces co mprised of 2 or more pieces of re troreflective sheeting on reinforced panels, carefully match adjacent pieces of sheeting for color to provide uniform appearance and brilliance under both day and night illumination. Any apparent contrast be tween adjacent pieces of applied sheeting or panels is cause for rejection of the sign. Overlap pressure sensitive sheeting a minimum of 3/16 inch at splices. If heat activated sheeting is spliced, the minimum overlap is 3/16 inch. If adjacent sheets of heat activated sheeting are butted together, the gap between adjacent sheets may not exceed 1/32 inch. On reinforced panel signs, vertical splices a minimum of 4 feet apart are permitted. On flat sheet signs, 1 vertical or horizontal splice is permitted. Make horizontal lap splices with the uppermost piece overlapping the lower piece. Splicing is prohibited if the sign face is made using the reverse screen process. (5) Sign Legend and Border Details. Provide sign legend and border that complies with the requirements specified in the Contract Documents. Use capital letters and numbers that comply with the standard rounded capital letter alphabets in the latest edition of Standard Alphabets for Highway Signs. Use lowe r case letters that comply with the latest edition of Standard Lower Case Alphabet for Highway Signs. Use initial capital letters that are 1 ⅓ times the loop height of the lower case letters, from a modified seri es "E" alphabet in which the stroke width is increased to approximately 1/5 of the height of the letter or number. Make the sign face for flat sheet signs using one of these processes: Direct Screen: the legend and border color is applied to the face of th e sign by the silkscreen process. Reverse Screen: a transparent color is applied to the face of the sign by the s ilkscreen process to form the legend and border. Direct Applied: the legend and border is retrorefl ective sheeting applied to th e face of the sign by the appropriate methods. Digital Printing. Use the Direct Applied process to make the sign face for reinforced panel signs.
6.Application of Process Inks and Lettering Films. Use the color of film or ink to obtain the sign face, legend and border as shown in the Contract Documents. Apply process inks to the sign faces accordin g to the retroreflective sheeting manufacturer’s recommendation, or by a meth od that will produce an equiva lent result. Apply lettering films to the sign faces according to the lettering film manufacturer’s recommenda tion, or by a method that will produce an equivalent result. 812 - PERMANENT SIGNING
800-40 (7) Sign Identification. Install a clear or light colored, pressure sensitive decal with a printed (not
handwritten) black legend on the back of each sign, including the following information: Sign Number (by sign fabricator) Erection Date (by sign installer) (month-day-year)* *A punch-out-the-date option may be used. Locate the legend horizontally, vertically or diagonally along the bottom or right edge of the sign in a position that is not covered up when the sign is installed. On a sign with an area of less than 16 square feet, the legend shall be a minimum of ½ inch in height. On a sign with an area of 16 square feet or more, the legend shall be a minimum of 1 inch in height.
8.Sign Overlays. Provide sign overlays that comp ly with the Contract Documents. Fabricate the sign overlays from flat sheet blanks covered with retroreflectiv e sheeting. Prepare the flat sheet blanks and apply the retroreflective sheeting as specified for flat sheet signs. Apply the legend an d border to the retroreflective sheeting as specified for the flat sheet sign.
9.Delineators. Provide the types of delinea tors specified in the Contract Documents. Fabricate delineators for steel post mount or bracket mount from flat sheet blanks covered with retroreflective sheeting. Prep are the flat sheet blanks and apply the retror eflective sheeting as specified for flat sheet signs.
10.Object Markers. Provide the type of object markers specifi ed in the Contract Documents. Fabricate Type 1 object markers from 18-inch by 18-inch flat sheet blanks covered with yellow high performance retroreflective sheeting. Fabricate Type 2 object markers from 6-inch by 12-inch flat sheet sign blanks covered with yellow high performance retroreflective sheeting. Fabricate Type 3 object markers from 12-inch by 36-inch flat sheet blanks covered with yellow high performance retroreflective sheeting with black non-reflec tive hash marks as shown in the Contract Documents. Prepare the flat sheet blanks and apply the retror eflective sheeting as specified for flat sheet signs.
11.Fabrication of Sign Posts. The total length of posts shown in the Contract Documents is estimated. The number, type and size of posts show n in the Contract Documents are determ ined from theoretical sections. Do not order sign posts until the Engineer provides the length of each post for th e sign or the sign assembly based on actual field measurements ( see subsection 812.3c. ). Wood posts, steel "U" posts and perforated square steel tube posts may be ordered in stock lengths and cut to the required length in the field. Do not torch-cut steel posts. Drill breakaway holes in the wood posts at the project site. Treat all field cuts and drilled holes in wood po sts with preservative material. Paint all cut ends of steel posts with zinc-rich paint. Fabricate steel beam posts, base plates and fuse plates to the specified dimensions. Drill the specified holes in the posts and plates. The preferred method of cutting pl ates is sawcuts; however, flame-cutting is permitted. Grind all edges smooth and remove all burrs projecting beyond the planes of the plate faces, cuts or drilled holes. After the base plates are galvanized, remove all runs or beads in the areas where washers are placed. 812.3 CONSTRUCTION REQUIREMENTS
a.General. Erect the permanent signing as necessary to expedite the completion of the project and the opening of the highway. The Engineer may require that the Contractor mobilize permanent signing operations whenever it is feasible to complete a portion of the project. The Contractor may have to mobilize and, upon completion of all currently feasible work, suspend the permanent signing operations more than once before the project is completed. It is the Contractor’s responsibl e to verify the utility locations. If a temporary sign interferes with the installation of a permanent sign, remove and reset the temporary sign to a location designated by the Engineer.
b.Sign Location and Orientation. Locate and stake each sign inst allation according to the Contract Documents. Orient the signs in relation to the highway alignment as shown in the Contract Documents. If the Contract does not include the item of Contractor Construction Staking, the Engineer will stake the location of each sign.
c.Sign Post Lengths. The Engineer will provide the Contractor with the length of each sign post.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 530–531 of 978.