9-28Signing Materials and Fabrication

9-28 Signing Materials and Fabrication9-28 Signing Materials and Fabrication

9-28.1 General

Unless noted otherwise in the Plans, permanent signs shall be constructed of sheet aluminum. Permanent signs which measure 36 inches or less on a side and are to be mounted on a single post may be constructed of single 0.135-inch fiberglass reinforced plastic panels. Sign overlay panels may be either 0.050-inch aluminum or 0.075-inch fiberglass reinforced plastic panels. All signs, except internally illuminated signs, shall be reflectorized. See ASTM D4956 for reflective sheeting type designations. Standard control signs and guide sign borders, letters, numerals, symbols, shields, and arrows shall be in accordance with the WSDOT Sign Fabrication Manual M 55-05. All STOP, YIELD, DO NOT ENTER, WRONG WAY, FREEWAY ENTRANCE, and HIGHWAY ENTRANCE signs shall be constructed entirely of Type IV reflective sheeting. All S series signs shall be constructed entirely of Type XI reflective sheeting unless otherwise specified. Overhead mounted warning signs with a yellow background shall use Type XI background reflective sheeting. Yellow overhead excit only panels shall use Type IV or XI reflective as shown in the Plans. Background reflective sheeting for all other signs shall be Type IV reflective sheeting or as noted in the Plans. Sign legends for all overhead signs shall be Type XI reflective sheeting, while legends on all other signs shall be constructed of Type IV reflective sheeting unless otherwise specified. Sign legends include: borders, letters, numerals, symbols, shields, and arrows. Reflective legend sheeting types shall not be mixed on individual signs.

9-28.2 Manufacturer’s Identification and Date

All signs shall show the manufacturer’s name and date of manufacture on the back. In addition, the width and height dimension, in inches, the Contract number, and the number of the sign as it appears in the Plans shall be placed using 3-inch series C black letters on the back of destination, distance, and large special signs. Hand painted numbers are not permitted.

9-28.3 Corner Radius

All regulatory and warning signs shall have rounded corners with the exception of stop signs. Information and guide signs may have square cut corners. Borders for signs having square cut corners shall have a corner radius approximately ⅛ of the lesser side dimension of the sign up to a maximum radius of 12 inches. For signs with rounded corners, the borders shall be concentric with the rounded corners.

9-28.4 Extruded Windbeams and “Z” Bar

All multiple post and multiple panel signs shall be constructed and installed with horizontal extruded windbeams and “Z” bar, when required, as shown in the Plans or the Standard Plans. All bolt and rivet heads visible on the sign face shall be anodized or painted to match the sign color area immediately surrounding the bolt or rivet head with the exception that rivet heads in the white colored sign areas shall be coated to match the white color or be uncoated rivet heads. Extruded windbeams and “Z” bar shall be accepted on the basis of a certificate of compliance from the manufacturer. Materials shall be as designated in Section 9-28.11 .

9-28.5 Letter and Spacing Formula

Letter and arrow sizes shall be as specified in the Plans. Spacing formulas shall be those furnished by the manufacturer of the letters. M 41-10 Page 9-141 Signing Materials and Fabrication 9-289-28.6 Destination Sign Messages Destination sign messages, borders, shields, and symbols shall be direct applied unless otherwise noted in the sign plans. All message components shall be one piece construction unless the least dimension exceeds available sheeting widths. All components shall have smooth, sharp cut edges. Components which are torn, wrinkled, or exhibit poor construction, will not be permitted.

9-28.7 Process Colors

Transparent and opaque process colors used in silk screening sign messages shall be as recommended by the manufacturer. When properly applied, process colors shall perform satisfactorily for the expected life of the sheeting. Applied colors shall present a smooth surface, free from foreign material, and all messages and borders shall be clear and sharp. Sheeting shall conform to the retroreflective minimum values and color limits established for its type and color without regard to whether the color is integral to the sheeting or achieved by applying transparent colors to silver/white sheeting. There shall be no variations in color, and overlapping of colors will not be permitted. Properly applied and cured process colors shall exhibit no blistering, bubbling, or loss of color or transparency when cleaned with a mild non-abrasive detergent solution. Minor loss of color may be detected when solvents such as kerosene, mineral spirits, heptane, or VM&P Naphtha are used to clean severely contaminated signs; e.g., paint vandalism. However, the colors shall not blister, bubble, peel, or be easily removed.

9-28.8 Sheet Aluminum Signs

Sheet aluminum signs shall be constructed of material conforming to ASTM B209 alloy 6061-T6 or alloy 5052-H36 or H38. Alloy 5005-H34 may be used for sign overlays. The Contractor shall provide a mill test certificate from the aluminum manufacturer attesting to the correct alloy and temper of the metal supplied, when requested by the Engineer. After the sheeting has been fabricated, the surface of each panel shall be protected from corrosion. The corrosion protection shall meet the requirements of ASTM B449 Class II Specification for Chromates on Aluminum. Aluminum signs over 12 feet wide by 5 feet high shall be comprised of vertical panels in increments of 2, 3, or 4 feet wide. No more than one 2-foot and/or 3-foot panel may be used per sign. The Contractor shall use the widest panels possible. All parts necessary for assembly shall be constructed of aluminum, galvanized steel, or stainless steel in accordance with the Plans. Sheet thickness shall be as follows: Maximum Horizontal Dimension Sheet Aluminum Thickness Overlay panels 0.050 inch Up to 20 inches 0.063 inch 20 to 36 inches, inclusive 0.080 inch Over 36 inches (Permanent Signs) 0.125 inch The side dimension for a diamond shaped warning sign is considered to be the maximum horizontal dimension. Before placing aluminum in contact with untreated steel, the steel surfaces shall be protected by proper cleaning and painting with one coat of paint conforming to Section

9-08.1(2)B and two coats of aluminum paint.

Metal shall be handled by device or clean canvas gloves between all cleaning and etching operations and the application of reflective sheeting. Page 9-142 M 41-10

9-28 Signing Materials and Fabrication9-28.9 Fiberglass Reinforced Plastic Signs

Fiberglass reinforced plastic signs and overlay panels shall be constructed of a fiberglass reinforced thermoset polyester laminate. The sign panel shall be acrylic modified and UV stabilized for outdoor weathering ability. The sign panel shall be stabilized to prevent the release of migrating constituents (such as solvents, monomers, etc.) over the expected life of the sign. The sign panel shall contain no residue release agents on the surface of the laminate so neither migrating constituents or release agents will be present in amounts which will interfere with any subsequent bonding operations. The sign panel shall not contain visible cracks, pinholes, foreign inclusions, or surface wrinkles that would affect implied performance, alter the specific dimensions of the panel, or otherwise affect its serviceability. The sign panel surface shall be wiped clean with a slightly water dampened cloth before applying reflective sheeting.

9-28.9(1) Mechanical Properties

All mechanical properties are stated as minimum requirements. The mechanical properties are measured in both the line direction of the panel and at 90 degrees to the line as noted in the appropriate ASTM test referenced. Mechanical Property Ave. Min. Requirement ASTM Test Tensile Strength 10.0 psi × 103 D638 Tensile Modulus 1.2 psi × 106 D638 Flexural Strength 20.0 psi × 103D790 Flexural Modulus 1.2 psi × 106 D790 Compression Strength 32.0 psi × 103D695 Compression Modulus 1.4 psi × 106 D695 Punch Shear 12.0 psi × 103 D732

9-28.9(2) Physical Properties

Sign Panels are to be 0.135 inch thick. Overlay panels are to be 0.075 inch thick. Panel thickness tolerance shall be plus or minus 0.005 inch. Panel tolerance on nominal length and width shall be plus or minus ⅛ inch for dimensions of 12 feet or less and shall be within ⅛ inch of square per 12 feet of length when measured in accordance with ASTM D3841. Panels shall be manufactured with smooth surfaces on both top and bottom of the panel. Panel flatness of a 30 by 30-inch panel shall be measured by hanging the panel diagonally in suspension. The maximum deflection measured diagonally, parallel and perpendicular to the panel by lines drawn through the center of the panel, shall not exceed ½ inch. The panel shall then be hung diagonally in suspension in an oven for 48 hours at 180°F. The maximum deflection shall again be measured as previously noted and shall not exceed ½ inch. All measurements shall be made when panels are at ambient temperature. Panels shall be pigmented to a visually uniform gray color within the MunselR range of N.7.5/to N.8.5/. Panels shall have a maximum coefficient of lineal thermal expansion of 1.8 × 10-5 in/in/°F. when tested in accordance with ASTM D696. Panels shall be classified as to a minimum Grade II (weather resistant) panel as specified in ASTM D3841 following 3,000 plus or minus 100 hour weatherometer test. M 41-10 Page 9-143 Signing Materials and Fabrication 9-28Panels shall contain additives designed to be less responsive to fire ignition and flame propagation. As such, the extent of burning shall not exceed 1.0 inch when tested in accordance with ASTM D635. Panels shall resist the impact energy of 20 foot-pounds applied with a hemispherical tipped object 1 inch in diameter. The panels thermal stability for strength and impact resistance qualities shall not be appreciably affected over a temperature range of -65ºF to 212°F. Fiberglass reinforced plastic panels for signs shall be accepted on the basis of a certificate of compliance from the manufacturer as outlined in Section 1-06.3 .

9-28.10 Digital Printing

Transparent and opaque durable inks used in digital printed sign messages shall be as recommended by the manufacturer. When properly applied, digital printed colors shall have a warranty life of the base retroreflective sign sheeting. Digital applied colors shall present a smooth surface, free from foreign material, and all messages and borders shall be clear and sharp. Digital printed signs shall conform to 70% of the retroreflective minimum values established for its type and color. Digitally printed signs shall meet the daytime color and luminance, and nighttime color requirements of ASTM D 4956. No variations in color or overlapping of colors will be permitted. Digital printed permanent traffic signs shall have an integrated engineered match component clear protective overlay recommended by the sheeting manufacturer applied to the entire face of the sign. On Temporary construction/maintenance signs printed with black ink only, the protective overlay film is optional, as long as the finished sign has a warranty of a minimum of three years from sign sheeting manufacturer. All digital printed traffic control signs shall be an integrated engineered match component system. The integrated engineered match component system shall consist of retroreflective sheeting, durable ink(s), and clear overlay film all from the same manufacturer applied to aluminum substrate conforming to Section 9-28.8 . The sign fabricator shall use an approved integrated engineered match component system as listed on the Qualified Products List (QPL). Each approved digital printer shall only use the compatible retroreflective sign sheeting manufacturer’s engineered match component system products. Each retroreflective sign sheeting manufacturer/integrated engineered match component system listed on the QPL shall certify a Contracting Agency approved sign fabricator is approved to operate their compatible digital printer. The sign fabricator shall re-certify annually with the retroreflective sign manufacturer to ensure their digital printer is still meeting manufacturer’s specifications for traffic control signs. Documentation of each re-certification shall be submitted to the QPL Engineer annually. Page 9-144 M 41-10

9-28 Signing Materials and Fabrication9-28.11 Hardware

Bolts, nuts, locknuts, and washers shall be of the same material for each attachment. Bolts, nuts, locknuts, and washers for signs mounted on overhead sign structures (i.e., sign bridges, cantilevers sign structures, and bridge mounted sign brackets) shall be stainless steel only. Hardware Specification Bolts ASTM F468 2024-T4 Aluminum ASTM A307 Steel ASTM F593 Group 1, Condition A Stainless Steel, or ASTM A193, Grade B8, Class 1 Stainless Steel U-bolts ASTM A276 Type 304 Stainless Steel Washers ASTM B209 2024-T4 Aluminum ASTM F844 Steel ANSI B18.22.1 Stainless Steel Alloy 304 Nuts ASTM F467 2024-T4 Aluminum ASTM A563 Grade A Steel ASTM F594 Group 1 Stainless Steel, or ASTM A194 Grade 8 or 8A Stainless Steel Locknuts (with nylon insert unless otherwise in the Plans)ASTM F467 2024-T4 Aluminum ASTM A563 Grade A Steel ASTM F594 Group 1 Stainless Steel, or noted ASTM A194 Grade 8 or 8A Stainless Steel Rivets ASTM B316 5052 Aluminum Alloy ASTM B316 5056 Aluminum Alloy Post Clips ASTM B179 356-T6 Aluminum Windbeams ASTM B221 6061-T6 Aluminum Angle and “Z” Bar ASTM B221 6061-T6 Aluminum ASTM A36 or ASTM A992 Steel Strap and Mounting BracketASTM A666, Type 201 Stainless Steel All steel parts shall be galvanized in accordance with AASHTO M111. Steel bolts and related connecting hardware shall be galvanized in accordance with ASTM F 2329.

9-28.12 Reflective Sheeting

Reflective sheeting material shall conform to ASTM D4956 - Standard Specification for Retroreflective Sheeting for Traffic Control. The following standard reflective sheeting types have been modified to reflect Contracting Agency requirements: Device Type Use Sheeting Color Sheeting Types Permanent Signing Permanent Signing All All IV1 Object Markers All All IV Temporary Construction Signing Warning Signs All Fluorescent OrangeVIII, IX, X2, XI Regulatory Signs All White IV Regulatory Signs Rural White II3, IV M 41-10 Page 9-145 Signing Materials and Fabrication 9-28Device Type Use Sheeting Color Sheeting Types Regulatory Signs Urban/Rural White II3, IV Regulatory Signs All Red III, IV Regulatory Signs All Green II, IV Regulatory Letters, Border or Symbols- Green III3, IV Temporary Construction Signs All All Other Background ColorsIII3, IV Other Devices Barricades All White or Orange III3, IV Barrier Delineators All White or Yellow III, IV, V, XI Bollards All All IV Flexible Guidepost All All III, IV, V Pedestrian Channelization DevicesAll White or Orange III3, IV Signal Backplates Portable Signals IV Signal Backplates Permanent SignalsSee Section

9-29 16

Tall Channelization Devices - 42-inchAll Fluorescent Orange/WhiteIII4, IV4, VIII, IX, XI Traffic Cones 28-inch and 36- inchAll White or Higher WhiteIII3, IV Traffic Safety Drums All Fluorescent Orange/WhiteIII4, IV4, VIII, IX, XI4 Transportable Attenuators All Yellow and Black ChevronIII3, IV Transportable Attenuators All White and Red ChevronIV Tubular Markers (portable or pavement mounted)All White or Yellow III3, IV Utilities Attached to Bridges I, See Section

6-01 10

9-28 Signing Materials and Fabrication9-28.12(1) Application

The reflective sheeting shall be applied in the manner specified by the sheeting manufacturer. The applied sign face shall not have bubbles, wrinkles, or foreign material beneath the reflective sheeting.

9-28.12(2) Edge Treatment

All edges and splices of reflective sheeting signs shall be coated with an edge sealer when recommended by the manufacturer of the reflectorized sheeting.

9-28.12(3) Splices and Color Matching

Splicing of reflective sheeting shall not be permitted on signs or panels with dimensions up to and including 48 inches in height or width unless the reflective sheeting specified does not come in this width, then the widest width material shall be used. When sheeting joints are required, they shall be lap-jointed with the top sheet overlapping the bottom sheet by no less than 3⁄16 inch. The fabricator shall endeavor to use the least number of seams possible with the horizontal lap preferable. Roller applied or reverse screened sheeting may be butt-jointed with joint gap not to exceed 1/32 inch. Color matching of adjacent sheets of reflective sheeting comprising a sign shall be accomplished without a noticeable difference in color. No borders shall be spliced other than the splice of the tangent border to the corner radius.

9-28.13 Demountable Prismatic Reflectorized Message and Borders

The letters, digits, and alphabet accessories shall consist of embossed 0.040-inch thick sheet aluminum frames conforming to ASTM B209 grade 3003-H14 in which prismatic reflectors are installed to prevent their displacement in handling or service. Letters in which reflectors are assembled by means of tape are unacceptable. The plastic reflectors face shall be colorless and be entirely smooth to present a water repellent and dirt resistant surface. The area indicating the letter shape that is not reflectorized shall be white for maximum daytime contrast with the sign background. All letters shall be free of any imperfections and shall present a high quality appearance. Demountable prismatic border shall be comprised of a minimum length of 2 feet with allowance of one shorter section between each corner radius. Letters shall be fastened to the sign with aluminum screws or blind rivets conforming to ASTM B209 grade 2024-T4. The coefficient of retroreflection of each reflex reflector intended for use in cutout letters, symbols, and accessories shall be equal to or exceed the following minimum values with measurements made with reflectors spinning. Observation Angle (Degrees)Entrance Angle (Degrees)Coefficient of Retroreflection Candle Power/ Square inch/Foot Candle 0.1 0 14.0 0.1 20 5.6 Failure to meet the specific minimum values shall constitute failure of the reflector being used. Upon failure of more than two of the 50 samples tested, a resample of 100 reflectors shall be tested. Failure of more than four of these samples shall be cause for rejection of the lot.

9-28.14 Sign Support Structures

All sign support structures shall be constructed as shown in the Plans. M 41-10 Page 9-147 Signing Materials and Fabrication 9-289-28.14(1) Timber Sign Posts At the Contractor’s options, timber sign posts and mileposts shall be treated Douglas Fir or treated Hem-Fir meeting the grades specified in Section 9-09.2 . Douglas Fir and Hem- Fir posts shall be given a treatment in accordance with Section 9-09.3(1) . Preservative and retention shall be as shown in Section 9-16.2 for sawn posts.

9-28.14(2) Steel Structures and Posts

Truss chords, struts, and diagonals, end posts, and end post struts and diagonals for sign bridge structures and cantilever sign structures shall conform to either ASTM A36 or ASTM A53 Grade B Type E or S. The nominal pipe diameter and the pipe wall thickness shall be as shown in the Plans or Standard Plans. All other structural steel for sign bridge structures and cantilever sign structures shall conform to either ASTM A36 or ASTM A992. Truss member connection hardware shall conform to Section 9-06.5(3) . Pipe members for bridge mounted sign brackets shall conform to ASTM A53 Grade B Type E or S, and shall be Schedule 40 unless otherwise specified. All other structural steel for bridge mounted sign brackets shall conform to either ASTM A36 or ASTM A992. U bolts, and associated nuts and washers, shall be stainless steel conforming to Section 9-28.11 , and shall be fabricated hot. Anchor rods for sign bridge and cantilever sign structure foundations shall conform to Section 9-06.5(4) , including Supplemental Requirement S4 tested at -20°F. Nuts and washers for sign bridge and cantilever sign structure foundations shall conform to ASTM A563 Grade DH and ASTM F436, respectively. Steel sign structures and posts shall be galvanized after fabrication in accordance with AASHTO M111, unless noted otherwise in the Plans. All bolts, nuts, and washers shall be galvanized after fabrication in accordance with ASTM F2329. Unless otherwise specified in the Plans or Special Provisions, metal surfaces shall not be painted. Except as otherwise noted, steel used for sign structures and posts shall have a controlled silicon content of either 0.00 to 0.06 percent or 0.15 to 0.25 percent. Steel used for slip bases (SB-1, SB-2, SB-3) and heavy-duty anchors shall have a controlled silicon maximum of 0.40 percent. If the Plans or Special Provisions specify painting of the galvanized steel surfaces, then the controlled silicon content requirement does not apply for those steel members. Mill test certificates verifying the silicon content of the steel shall be submitted to both the galvanizer and the Engineer prior to beginning galvanizing operations. Minor fabricating and modifications necessary for galvanizing will be allowed if not detrimental to the end product as determined by the Engineer. If such modifications are contemplated, the Contractor shall submit a Type 2 Working Drawing of the proposed modifications.

9-28.14(2)A Monotube Sign Bridge and Cantilever Sign Structures

Structural steel, except for cover plates, anchor rod templates and as otherwise shown in the Plans, shall conform to either ASTM A572 Grade 50, or ASTM A588. Cover plates shall conform to ASTM A36. Handhole cover screws shall conform to ASTM F593, Grade 1.Sign bracket bolts, nuts, and washers shall conform to Section 9-06.5(1) . Monotube splice bolts, mounting beam bolts, and associated nuts and washers, shall conform to ASTM F3125 Grade A325, and shall be galvanized after fabrication in accordance with ASTM F2329. Tension control bolts conforming to ASTM F 3125 Grade F1852 may be used as monotube splice bolts, and if used shall be galvanized after fabrication in accordance with ASTM B695 Class 55 Type I. Monotube sign bracket rods shall conform to Section 9-06.5(1) and shall be galvanized after fabrication in accordance with ASTM F2329. Page 9-148 M 41-10

9-28 Signing Materials and FabricationAnchor rods and associated nuts and washers shall conform to Section 9-06.5(4) with

supplemental requirement S4 tested at -20°F. Anchor rods shall be galvanized a minimum of 1’-0” at the exposed end in accordance with ASTM F2329. Nuts and washers shall be galvanized in accordance with ASTM F2329.

9-28.14(3) Aluminum Structures

Welding of aluminum shall be in accordance with AWS D1.2/D1.2M, latest edition, Structural Welding Code – Aluminum. Aluminum alloy filler metals utilized on anodized structures shall result in color matching to base metals.

9-28.15 Vacant