chap_14_manufacturing_specification.pdf

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Chapter 14 Manufacturing Specifications

December 2005

14.1 General

The following specifications apply to all Forest Service sign manufacturing, whether by Federal or state prison industries, commercial sign shops, or force account operations.

14.2 Applicable Documents and References

The following specifications, standards, and references form a part of this document to the extent specified herein. Unless otherwise specified, the applicable documents and references are those in effect on the date of the sign requisition, invitation to bid, or request for proposal.

14.2.1 U.S. Government Documents

USDA Forest Service

• Forest Service Sign Handbook, EM-7100-15 Sign and Poster Guidelines for the Forest Service.

U.S. Department of Transportation Federal Highway Administration (FHWA)

• FP-03 – Standard Specification for Construction of Roads and Bridges on Federal Highway Projects (latest edition), Section 718 Traffic Signing and Marking Material, and Section 633 Permanent Traffic Control, ISBN No. 0-16-051430-4.

FP-03 is available from the Superintendent of Documents, U.S. Government Printing Office, www.bookstore.gpo.gov or phone (866) 512-1800.

• MUTCD – Manual on Uniform Traffic Control Devices for Streets and Highways (2003 or latest edition).

The 2003 MUTCD is available on the Internet and by sale from organizations such as the American Traffic Safety Services Association (ATSSA). (540) 368-1701 or http://www.atssa.com

• Standard Highway Signs, Stock No. 950-044-00000-4 or latest edition.

Federal Standards and Specifications

• MMM-A-181D – Adhesives, Phenol, Resorcinol, or Melamine Base (latest edition)

• TT-P-19D(1) – Paint, Latex (Acrylic Emulsion, Exterior) superseded by;

• A-A-3183 – Paint, Latex, Exterior, (For Wood and Masonry), (latest edition)

• A-A-2336 – Primer Coating (Alkyd, Exterior Wood, White and Tints), (latest edition)

• FED-STD-595 – Colors Volume 1 (latest edition)

Color Numbers (all) Color Number 20059 Brown Stain Color Number 36357 Gray Stain

• FED-STD 595B – Color Chips – Fan Deck, Stock Number 7690-01-162-2210

The above documents and federal color chips are available from the General Services Administration, Federal Supply Service FSS Acquisition Management

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Center, Environmental Programs and Engineering Policy Division (FCOE), Washington, DC 20406.

14.2.2 Nongovernment Publications

APA The Engineered Wood Association

• PS1-95 – Construction and Industrial Plywood available from, APA U.S.

Headquarters and International Marketing Division, 7011 South 19th Street, P.O. Box 11700, Tacoma, WA 98411-0700.

American Society for Testing and Materials (ASTM)

• D4956 – Standard Specification for Retroreflective Sheeting for Traffic Control, (latest edition). This specification covers various types of retroreflective sheeting. Refer to the section on sheeting in this chapter.

• B209 Standard Specification for Aluminum-Alloy Sheet and Plate, (latest edition), 5052-H38 Aluminum Plate, 6061-T6 Aluminum Plate

Copies of these specifications are available for purchase from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.

14.3 Retroreflective Signs

14.3.1 Description

All materials, labor, tools, equipment, and supplies used to manufacture retroreflective signs as well as their packaging and shipment to the designated destination must comply with this specification, drawings, and other specifics of the requisition. There can be no marks, blemishes, or damage of any kind that may result in noticeable defects on any of the surfaces of the finished product. If not specifically defined herein, the contracting officer will pre-approve repair and/or method of repair of defects.

14.3.2 Substrate

High Density Overlay (HDO) plywood – Overlay color may be either black or buff unless otherwise specified. Minimum 1/2-inch plywood shall be used for signs less than 24 inches in longest dimension. Minimum 5/8-inch plywood shall be used for all other signs cut from a single sheet of plywood. Three-quarter-inch HDO plywood shall be used for all signs requiring joining.

Aluminum – The aluminum substrate shall be alloy 5052-H38 or 6061-T6 from flat sheet stock conforming to the requirements of ASTM B209 and FP-03 section 718.05. Minimum thickness shall be 0.8 inch for panels up to 30 inches and 0.12 inch for larger panels. The back side of the sign shall not be painted.

Fiberglass-reinforced plastic (FRP) – Fiberglass reinforced plastic shall comply with the recommendations of the Fiberglass Reinforced Panel Council publication Recommended Traffic Control Sign Panel Specification. Unless otherwise specified in the contract, the color of the material shall be brown, matching Federal Standard 595a, color #20059, or an alternative brown color approved by the contracting officer. Use a minimum thickness of 0.08 inch for signs 12 inches and under, 0.12 inch for signs with the largest dimension between 12 and 24 inches, and 0.135-inch-thick panels for signs exceeding 24 inches in any dimension.

Plastic banner type signs – Refer to Section 14.6.

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Wood-plastic composite (WPC) – WPCs are a composite of wood fibers mixed with thermoplastic resins. Initial testing indicates WPC is a satisfactory substrate for retroreflective signs, although it is a somewhat heavier substrate than plywood. When specified as a substrate for signs, the WPC shall contain a minimum of 50 percent wood fibers. Wood flour or finer ground wood products are not to be used because they produce lower mechanical strengths in the composite substrate. The composite material shall be either tan or brown in color and may be manufactured using compression molding, extrusion, or injection molding. Thickness for the substrate shall be the same as for the applicable HDO plywood substrate signs described in Section 14.3.9a.

14.3.3 Sheeting

All retroreflective materials (sheeting, legend, borders, and symbols) shall conform to FP-03 or the latest edition and ASTM D 4956. All sheeting shall be engineering grade ASTM Type I, sheeting for informational and directional signs.

Warning and regulatory signs shall be ASTM Type III, high-intensity sheeting, unless another type of sheeting (Table 3-3) is specified. Background sheeting shall be pressure sensitive.

14.3.4 Clear Overlay Sheeting

When specified, cover the entire face of a sign with a clear UV-stabilized, pressure-sensitive adhesive, protective overlay film. Use 3M Protective Overlay Film Series 1160 or equivalent, which will significantly increase the durability and life of the sign. This film is a durable, high-performance, solvent-resistant, clear sheeting. Overlay sheeting significantly extends the life of a sign manufactured with pressure-sensitive letters and characters, especially when installed in areas where the sign is subjected to snow burial. Sign defacement from graffiti or other vandalism can often be cleaned from this overlay film.

Overlays also reduce sign damage from paintball gun impacts. The film shall cover the top of the sign and extend 1 inch down the back side of the sign.

14.3.5 Top Edge Film

When specified, top-edge film shall be vinyl that is pressure-sensitive, premium-quality, clear, and ultraviolet-resistant. Top-edge tape extends the life of signs with HDO substrates and retards peeling or delamination of the pressure-sensitive background sheeting from the substrate of the sign. It should normally be specified for signs, regardless of the substrate, at higher elevations subject to snow and in wet and damp climates. Top-edge film is not needed when specifications call for clear overlay sheeting to be applied over the face and top of the sign.

14.3.6 Fonts

Unless otherwise specified, text for legends shall be Highway Gothic, ASA Series C lettering for 3-inch and 4-inch characters. Series D lettering should be used on 5-inch and 6-inch characters. Characters that are 7 inches and above should use Series E lettering. Directional and guide signs shall be in all capital letters as shown in the MUTCD, Figure 2H-2. General forest Information signs not covered by MUTCD may use upper- and lower-case text.

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14.3.7 Paint

Paint applied to any surface of the substrate shall be premium grade exterior, silicone alkyd enamel. Colors should match the color of the HDO plywood substrate or sheeting, as specified in the order.

14.3.8 Silk-screen Inks

Refer to FP-03, Section 718.11(a).

14.3.9 Manufacturing Requirements

14.3.9a Sign Panel Preparation

Sign panels shall be cut from the specified substrate material that is flat and free of warp or any defects that interrupt smooth continuity of the panel surface. All panels shall be prepared precisely as described in writing by the substrate and sheeting manufacturers. The sign manufacturer shall assure that the reflective sheeting is applied to the proper side of the substrate where applicable. Sign panels less than 4 by 8 feet shall be cut from a single sheet of substrate material without joints.

HDO sign panels larger than 4 by 8 feet shall be fabricated in sections using 3/4-inch thick HDO substrate material. Individual panel sections shall be prepared so they can be joined using doweled butt joints. Dowels shall be 3/8-inch threaded metal bolt stock, 4 1/2 inches in length, placed 2 inches from each side and every 12 to 15 inches along the joint. See Figure 14–1 for typical details. Actual joining of the individual panels shall occur during sign installation.

14.3.9b Sizing Tolerance

Dimensions for sign panels shall be as shown on the detail drawings, with a tolerance of ± 1/4 inch. Panel thickness shall be as follows:

• HDO plywood – Minimum 1/2-inch plywood shall be used for signs less than 24 inches in longest dimension. Minimum 5/8-inch material shall be used for all other signs cut from a single sheet. Three-quarter-inch plywood shall be used for all signs requiring joining.

• Aluminum – Refer to FP-03, Section 718.05. Aluminum panels shall be a minimum thickness of 0.08 inch and panels of 30 inches in any dimension shall be 0.12-inch thick.

• Reinforced Fiberglass – Reinforced fiberglass panels shall be 0.08-inch thick for signs 12 inches and under, 0.12 inch for signs with the largest dimension between 12 to 24 inches, and 0.135-inch thick panels for signs exceeding 24 inches in any dimension. Refer to FP-03 Section 718.06(b) for additional requirements.

14.3.9c Beveling/Corner Rounding

All edges of sign plywood panels shall be slightly rounded or beveled (typically, 45 degrees by 1/16 inch) to eliminate edge sharpness. Each corner radius shall be as specified in the drawings.

14.3.9d Drilling

Holes, when required, shall be drilled at the locations and to the sizes shown on the drawings. All holes shall be deburred such that all burrs and sharp edges are removed.

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14.3.9e Edge Finishing

All core-gap holes on HDO plywood signs shall be filled with an exterior wood filler. Sign edges shall be sanded with sandpaper (60 to 80 grit) to produce a smooth surface and shall receive one coat of paint before application of background sheeting. (See Section 14.3.9h for final edge finishing).

14.3.9f Sheeting, Legend, Border, and Symbol Application

All sheeting, legend, borders, and symbols shall be applied precisely as prescribed in writing by the manufacturer of the material being used.

The entire face of the sign panel shall be covered with one unspliced sheet;

however, splicing is permissible where the substrate panel exceeds 48 inches in vertical dimension. Only horizontal splicing shall be used. Materials shall be color matched by use of sheeting from the same factory lot number and manufacturing date, and the splice shall not coincide with any legend. The top piece shall overlap the bottom piece by a minimum of 1/2 inch. See Figure 14-1.

All letters, layout, and spacing requirements for guide and information signs shall conform to the Standard Alphabets for Highway Signs, FHWA, current edition, and as shown on drawings. Use Highway Gothic ASA Series lettering as specified in Section 14.3.6 unless otherwise specified.

The following tolerances shall apply:

• Legend, numerals, and symbols shall be horizontally aligned to a tolerance of ± 1/16 inch.

• Legend, numerals, and symbols shall be vertically aligned to a tolerance of ± 1/16 inch.

• Spacing between lines shall not exceed a tolerance of ± 1/16 inch.

Protective overlay film and borders shall be applied in the following order to create a shingling effect:

Top of sign

Sheeting or overlay

1/2 in. minimum overlap

Substrate

Apply lower sheeting or overlay first. Overlap by 1/2 in. minimum with top sheeting.

Figure 14-1—Sheeting or overlay overlap detail.

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1. Apply bottom border strip and trim to outside edge of substrate.

2. Apply bottom corners (radius) and trim to outside edge of substrate.

3. Apply left and right border strips and trim to outside edge of substrate.

4. Apply top corners (radius) and trim to outside edge of substrate.

5. Apply top border strip and trim to outside edge of substrate.

6. If specified in the requisition, apply clear protective overlay film over the entire face of the sign.

7. Apply edge film, when specified on the requisition, over the top edge of the panel as follows:

Edge film widths shall be selected as follows:

Sign panel thickness Edge film width (inches) (inches)

1/16 – 3/8 1

1/2 – 5/8 2 3/4 - 1 3

Edge film shall be applied to extend a minimum of 1 inch below the top corner radius on each side of the panel.

14.3.9g Silk-screening

Refer to FHWA FP-03, Section 718.11

14.3.9h Trimming and Edge Finishing

After all sheeting, legends, borders, and symbols have been applied to the substrate, all excess material shall be trimmed flush with the edge of the sign panel, except sheeting may overlap HDO plywood substrate edges by 1/8 inch.

After trimming, the edges of HDO plywood substrate signs shall be finished with a second coat of paint applied in accordance with the recommendations of the paint manufacturer.

14.4 Routed Signs

14.4.1 Description

All materials, labor, tools, equipment, and supplies used to manufacture routed signs as well as their packaging and shipment to the designated destination must comply with this specification, drawings, and other specifics of the requisition. Workmanship shall be high quality with no visible defects in the finished product.

14.4.2 Substrate

The manufacturer shall obtain approval from the contracting officer to use substrate materials other than those defined herein for sign manufacture.

Cleats shall be of the same material and specifications as the material in the sign panel.

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December 2005

Medium Density Overlay (MDO) plywood – MDO plywood shall be all Douglas fir, grade B, plugged core or better, exterior type, and B-B (or better) face and shall otherwise conform to U.S. Product Standard, PS-1, current edition. Three-quarter-inch material shall be seven-ply, and 1-inch material shall be nine-ply. The resin-treated MDO facing shall be on both sides of the finished product and shall present a smooth, uniform surface intended for high-quality paint finishes. Each panel edge brand shall include the following: MDO B-B G1

EXT APA PS-1.

Lumber – Lumber shall be cedar or oak as specified on procurement documents. Other species of lumber may be used for one-board signs when specified in procurement documents.

Cedar – Cedar shall be grade marked Western Red Cedar (Thuja plicata), clear heart or A-grade, vertical grain, kiln dried, nominal thickness of 2 inches, and in accordance with Grading Rules for West Coast Lumber, West Coast Lumber Inspection Bureau, current edition, including any supplements thereto, except that the moisture content shall not exceed 15 percent at the time of sign manufacture.

Oak – Oak shall be white oak, No. 1 grade, with a nominal thickness of four quarters (1 inch). Red oak may not be substituted because it has inferior resistance to decay in outdoor exposures.

Wood-plastic composite (WPC) – WPCs are a composite of wood fibers mixed with thermoplastic resins. WPC is somewhat heavier than plywood. When specified as a substrate for signs, the WPC shall contain a minimum of 50 percent wood fibers. Wood flour or finer ground wood products are not to be used because they produce lower mechanical strengths in the composite substrate. The composite material shall be either tan or brown in color, and may be manufactured using compression molding, extrusion, or injection molding.

Thickness for the substrate shall be the same as for the applicable MDO plywood substrate signs.

High-density polyethylene (HDPE or recycled plastic) – This nonbiodegradable plastic is extremely durable and requires little or no maintenance. It will not crack, warp, oxidize, rust, break, or suffer UV deterioration. It withstands temperatures as low as minus 40 degrees Fahrenheit and repels graffiti. It has some flexible characteristics and may require metal or wood reinforcement for proper support. Follow manufacturers recommendations for proper mounting, maintenance, and repair.

Up to three layers of polyethylene are bonded through an extrusion process called “A/B/A” format. The surface “A” is one color with a contrasting core “B” underneath. The surface can be routed to expose the core color underneath or the surface material around the legend can be routed away leaving a raised surface in the “A” color. The HDPE sheets consist of a 1/8-inch top layer, a 1/2-inch middle core layer, and a 1/8-inch bottom layer. The combination of layers shall provide a unified 3/4-inch thick panel free of any jointing, unless requested for oversized signs. The material is produced in solid sheets that is 5 feet by 10 feet by 3/4-inch thick.

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Fiberglass reinforced plastic (polyethylene) (FRP) – This is an exceptionally strong composite made from fiberglass reinforced in a plastic (polymer) matrix.

The extremely durable material requires little or no maintenance. Complex forms and shapes are easily molded such as Forest Service shields. It will not crack, warp, oxidize, rust, break or suffer UV deterioration. It has superior corrosion and chemical resistance and repels graffiti. Follow manufacturers recommendations for proper mounting, maintenance, and repair.

See Section 14.5.

14.4.3 Adhesive

The adhesive (glue) shall be phenolic resorcinol, moisture resistant in accordance with Federal Specification MMM-A-181C.

14.4.4 Hardware

All hardware (such as screws, bolts, and washers) shall be zinc plated.

14.4.5 Primer, Paint, and Stain

Primer – Primer shall be top-quality and oil-based conforming to Federal Specification TT-P-25.

Paint – Paint shall be top-quality exterior acrylic (high-acrylic) latex enamel conforming to Federal Specification TT-P-19. Unless shown otherwise in drawings, colors shall be Federal Standard 595, as follows:

Pantone Matching Color 595 No. System (PMS)

Brown 20059 476 opaque Yellow-cream 23695 Orange 12473 White 27875 Light Blue 15187 Black 17038 Green 14260 Tan 20260 Seminole Brown 20109 Gray White 27722

These lists are not all-inclusive; drawings may specify other colors.

The five-digit numbering system used for the colors is based on the assignment of numerals, which indicate the following:

1. The first digit indicates the category of finish; 1—full gloss; 2—semigloss;

3—lusterless (flat).

2. The second digit indicates the selected color classification group.

3. The last three digits indicate the approximate order of increasing (diffuse) reflectance.

Stain – Stain shall be semitransparent, oil based. The final product shall match the following colors:

• Gray stain. Gray stain shall match Federal Standard 595, No. 36357.

• Brown stain. Brown stain shall match Federal Standard 595, No. 20059.

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14.4.6 Manufacturing Requirements

14.4.6a Medium-Density Overlay Plywood

Sign board panels less than 4 by 8 feet shall be cut from a single sheet (minimum 3/4-inch thick) substrate material (without joints) and shall be flat and free of warp or any defects that interrupt smooth continuity of the panel surface.

Joining will be permitted only on those sign board panels exceeding 4 by 8 feet.

One-inch-thick material shall be used for all MDO signs requiring joints.

Only doweled butt joints shall be used. Dowels shall be 3/8-inch threaded bolt stock, 4 1/2 inches in length, placed 2 inches from each side and every 12 to 15 inches along the joint. See Figure 14–2 for details. A doweling jig shall be used as a guide to drill dowel holes. All wood chips and sawdust shall be removed from the dowel holes and joint surfaces before joining. Dowels shall be dipped in glue before insertion.

All core-gap holes shall be filled with an exterior wood dough. All panel edges shall be sanded to eliminate edge sharpness but not to exceed one ply in depth.

Preparing, gluing, clamping, and finishing of the plywood panels shall be as described in other sections of this specification. Care shall be taken not to sand through the MDO overlay at the joint. Exposed surface wood is not acceptable on sign faces. Cleats should be done as shown in Figure 14-3.

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1 in. MDO plywood

Glue Dowel

3/8 in.

5 in. maximum 4 3/4 in. minimum 4 1/2 in.

2 1/4 in.

2 1/4 in.

Figure 14-2—Butt joint with dowels, MDO plywood.

60 in.-72 in.

Glue joint

See Figure 14-4 for cleat size, the number of cleats, and fastening information.

6 in. above glue joint 2 in. above glue joint 2 in. below glue joint 6 in. below glue joint

48 in.-60 in.

12 in.

Figure 14-3—MDO plywood cleating details.

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14.4.6b Lumber

Sign panels made of lumber shall be fabricated from boards not more than 8 inches nor less than 4 inches wide, except that Forest Service shields and trail signs up to 10 inches in height may be made from one board. Joined boards shall provide a smooth match on all surfaces. Joining of boards for sign panels shall be accomplished with plain joints, side grain to side grain. The surfaces to be joined shall be machined just before bonding. Only horizontal joints shall be permitted.

Preparation of surface joints – Surfaces to be glued shall be smooth, true, and free from machine-joining marks and chipped or loosened grain.

Temperatures – Air temperatures shall be not less than 70 degrees nor more than 90 degrees Fahrenheit, or as otherwise recommended by the adhesive manufacturer, during the glue application and curing process.

Glue application – The entire surface of each joint face shall be covered with the specified glue. The glue manufacturer’s recommendations concerning the amount applied, drying time, and other application procedures shall be followed.

Clamping and curing – A minimum of four clamps shall be used on sign panels less than 48 inches long. An additional two clamps shall be used for each 12 inches of additional length. Clamps shall be alternated on the front and back of the sign panel and tightened in dual sequence starting in the middle of the sign panel. All clamps shall be tightened to apply sufficient pressure to ensure tight joints without warping the panel. The clamps shall remain in place for a minimum of 12 hours or as recommended by the adhesive manufacturer, whichever is longer.

Surface and edge finishing – All surfaces shall be sanded to provide a smooth surface. Sawdust, wood chips, and so forth, shall be removed from all surfaces.

All exposed edges of the sign panel and cleats, when applicable, shall be routed with a corner-rounding bit (1/8 to 3/16-inch radius) to eliminate edge sharpness.

Cleating – Sign panels of more than one board shall have cleats attached on the back side (see Figure 14-4). Cleats for lumber signs shall be of the same lumber type as the sign panel. Nominal 1- by 4-inch cleats shall be used for signs less than 16 inches high or 36 inches wide. Nominal 2- by 4-inch cleats shall be used for signs up to 30 inches high or 60 inches wide. Nominal 2- by 6-inch size material shall be used for all larger signs.

Cleats shall extend vertically to within 1 inch of the top and bottom of the sign panel and shall be located approximately 2 inches horizontally from the sides of the panel. Sign panels less than 4 feet long shall have one cleat on each side.

Sign panels longer than 4 feet shall have additional cleats, equally spaced, so that the maximum distance between cleats does not exceed 3 feet. Cleats shall be predrilled with 1/4-inch holes and attached with No.12 or No.14 zinc-plated, hex-head screws. Fasteners shall be located at the center of each sign panel board and offset to prevent splitting. A single row of fasteners shall be used for 4-inch-wide cleats. A double row of fasteners shall be used for 6-inch-wide cleats. Do not place fasteners in glue joints.

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Use double row of fasteners with 6-in.-wide cleats.

Install third cleat when panel height exceeds 72 in. or panel length exceeds 84 in.

Less than 16 in. high or 36 in. wide

Up to 30 in. high or 60 in. wide

Larger than 30 in. high or 60 in. wide

General notes:

1. Cleats are also glued with specified glue.

2. Cleats are to be installed prior to routing.

3. Alternate screw tightening sequence from center of cleat outward to both ends.

4. Do not install screws in glue joint.

1 x 4

2 x 4

2 x 6

Sign size

2-in. inset from top and bottom of sign.

Make cleat radius even with panel radius.

See chart below for cleat size.

2-in. inset from sides of sign.

Sign face

Use single row of fasteners with 3-in.

or 4-in.-wide cleats.

Offset to prevent splitting.

Assembly and gluing for wilderness signs

Cleat #13 or #14 zinc plated, flat Phillips-head wood screws.

Pre-drill with 1/4-in. holes.

See chart

1 1/2 in.

3/8 in.-min.

Figure 14-4—Dimensional lumber cleating detail.

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14.5 Fiberglass Reinforced Plastic (FRP) Signs

This item consists of furnishing all materials, labor, tools, equipment, and supplies for the manufacture of Fiberglass Reinforced Plastic (FRP) signs in accordance with this specification, drawings, and as specified on procurement documents. Workmanship shall be high quality with no visible defects in the finished product. Fiberglass reinforced plastic signs shall be fabricated by hand layup. FRP may also be referred to as Glass Fiber Reinforced Polyethylene.

14.5.1 Design Requirements

Fiberglass reinforced plastic design shall follow the procedures and methods, utilize the equations and formulas, and incorporate the factors of safety and allowable design stresses and strains as set forth in ASTM D 4097, ASTM D 3299 and ASME RTP-1. Where design conflicts arise between the various standards, the most stringent design shall be used.

The design shall allow for the most severe combination of conditions, which may include any or all of the following:

• Superimposed loads such as those due to wind and seismic forces.

• Loads applied during transportation and erection.

• Thermal expansion and contraction.

14.5.2 Materials

• Resin used to fabricate the FRP sign shall be polyester for the structural layer.

• Catalysts and promoters shall be of the type and amount recommended by the resin manufacturer for use with their resin in the required service.

Positive measurement control of catalysts, promoters, and resins shall be maintained at all times.

• All secondary laminates in contact with the stored chemical shall be made with using the same resin as used in the corrosion barrier.

• Glass fiber reinforcement used shall be a commercial grade 1 1/2-ounce glass matte.

• Polyester gel coats shall be in standard colors, or as specified.

• Ten-pound density polyurethane foam shall be used for the interior reinforcements of single-faced signs.

14.5.3 Manufacturing Requirements

Fiberglass signs are manufactured by producing a wood-grained, routed face of the sign, backing it with a substrate material and laminating the whole product in fiberglass and resin.

Signs shall have the appearance of wood grain.

Sign colors shall be Federal Standard 595, Brown #20059 and yellow-cream #23695, or as specified.

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14.5.3a Single-faced Signs Construction

Sign faces shall receive a minimum of 11 mils of polyester gel coat, backed with a minimum of three layers of 1 1/2 ounces of fiberglass matte and laminating resin. Substrate material shall be 10-pound foam. Finish fiberglass thickness shall be 5/16 to 1/2 inch of fiberglass. Signs will be subsequently routed to a depth of 1/8 to 1/4 inch using Highway Gothic letter sizes and series specified for the sign. Foam shall be beveled at a 45-degree angle. Backing shall be fiberglass with another layer of 1 1/2-ounce fiberglass matte. The final layer of 1 1/2-ounce fiberglass matte shall be applied with the backing color mixed in the final resin for permanent color. Sign backing shall be brown in color.

14.5.3b Double-Faced Signs Frame Construction

Figure 14-5 shows typical construction details, which are as follows:

1. Interior channels in sign shall fit over 4- by 1 1/2-inch channels, spaced with a centerline-to-centerline dimension specified for the particular sign.

Channel height shall extend to within 2 inches of the top of the sign.

2. Frame size shall be appropriate for the sign. Substrate shall be 2 by 4 framing. Corners shall be manufactured from 4 by 4 or 4 by 6 treated material. Corners shall be curved. The frame shall be screwed together with 2 1/2-inch galvanized deck screws. Prepare one side of the frame with liquid nail compound. Install 1/8-inch plywood sheeting on the frame and staple in place. Use a roller panel router bit to trim the 1/8-inch plywood sheeting to fit the sign frame. Turn the frame over and drill 1/2- to 5/8-inch holes between each section so that the sign can breathe internally.

At the bottom of the sign, drill a 1-inch hole and insert a metal vent cap.

3. Completely brush interior with a thick coat of fiberglass resin to seal all interior framing. Completely brush a layer of fiberglass resin on the interior side of another piece of 1/8-inch plywood sheeting large enough to cover the open side of the sign. Let both sides dry completely.

4. Cut out the holes for the stanchion receptacle. Use liquid nails on the 2 by 4 section of the second side of the frame. Install 1/8-inch plywood sheeting and staple in place.

5. Cover one side of the sign with 1 1/2-ounce fiberglass mat and resin. Drape the material completely over the edges of the sign. Dry thoroughly. Once dry, turn sign over and trim excess. Repeat the fiberglass process on the reverse side, making sure that the edges are covered again. Two layers of 1 1/2-ounce mat shall be on the edges. Trim and clean up as necessary.

6. Sign faces shall receive 11 mils of polyester gel coat backed with a minimum of three layers of 1 1/2-ounce fiberglass mat and laminating resin.

Finish fiberglass thickness shall be 1/4- to 3/8-inch of fiberglass.

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14.5.3c Solid Sign Construction Solid fiberglass signs are cast 3/4-inch thick. Signs will be subsequently routed to a depth of 1/8 to 3/16 inch using Highway Gothic letter sizes and series specified for the sign.

The back of the sign shall be drilled 1/2-inch deep in 4 to 6 places as specified either by the manufacturer or the contract to allow insertion of 3/8-inch thread t-nuts to provide for easy mounting and to prevent the drilling of the sign face during installation. T-nuts shall be set in place by casting in polyester resin.

ATop

BottomCorner and sloping side

Corner and sloping side

Front of sign

Back of sign

Post slotPost slot

A

Front view of sign frame

Side view showing sign faces installed

(Section A-A)

Bottom view of sign frame

2 in. x 4 in. frame

Fr on t o f s ig n

B ac k of s ig n Corners made from 4 in. x 4 in. or 4 in. x 6 in.

treated material.

Post slot

Post slot Post slot

Figure 14-5—Typical construction details for fiberglass reinforced signs.

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14.5.4 Sign Message

The sign message shall be routed to a depth of 1/8 to 3/16 inch using Highway Gothic letters, sizes, and series specified for the sign. Do not route all the way through the fiberglass material. Fiberglass resin shall be puddled into the routed letters. Color shall be yellow-cream or as specified.

Install sign faces onto the substrate using a 1 1/2-ounce mat to secure sign face to the substrate. Repeat procedure to install the second face.

14.5.5 Maintenance

The fabricator shall provide instructions on the upkeep and maintenance of the fiberglass signs. Turtle Wax Formula 2001 with UV Protection is recommended for early sign maintenance and protection from UV damage. No painting is needed.

14.6 Flexible Banner Signs

Flexible plastic banners used to mark gates shall be manufactured from either polyethylene or polycarbonate materials having a minimum thickness of 0.055 inch and a maximum thickness of 0.125 inch. Unless otherwise specified, Type 1 engineer-grade retroreflective sheeting with red and white markings shall be applied to both sides of the banner. The stripes on the front shall slant downward to the right while the slants on the back shall slant downward to the left. The corners shall be square.

Three-spur grommets, with a minimum hole diameter of 1/4 inch, shall be placed at the corners. The hole shall be centered 3/5 inch from the edge with the corner grommets being centered 3/4 inch from both the vertical and horizontal edge.

Unless otherwise specified, banners exceeding 24 inches in any dimension, shall have additional grommets equally spaced around the perimeter of the sign.

The distance between grommets shall not exceed 24 inches.

Figure 14-6—Flexible plastic banner gate marker (6 inches x 12 inches).

3 inches

45° angle

FBM-12

6 inches

12 inches

Note: Front stripes slant downward to the right. Back stripes to the left.

14-17

December 2005

14.7 Legend, Layout, and Tolerances – All Signs

Dimensions of the sign panel shall be as shown in the drawings with a tolerance of ± 1/4 inch.

For information signs, all letters, layout, and spacing requirements shall conform to the Standard Alphabets for Highway Signs, FHWA, current edition, and as shown on drawings. Use Highway Gothic, Series C or D lettering unless otherwise specified.

The following tolerances shall apply:

• Legend, numerals, and symbols shall be horizontally aligned to a tolerance of ± 1/16 inch.

• Legend, numerals, and symbols shall be vertically aligned to a tolerance of ± 1/16 inch.

• Spacing between lines shall not exceed a tolerance of ± 1/16 inch.

14.7.1 Routing Wood and Fiberglass Signs

All letters, symbols, borders, separation lines, logotype, and so forth, on all signs, shields, and plaques shall be machine routed.

All letters, arrows, trees, borders, and so forth shall be routed with a vertical-sided flat-bottom bit. For letters larger than 3 inches, the finish-cut bit diameter shall be 1/4 inch. For letters less than 3 inches, the finish-cut bit diameter shall be 1/8-inch.

Routing depth shall be as shown below:

Desired Maximum Minimum (inches) (inches) (inches)

Lumber 1/8 1/4 1/8

MDO plywood 1/16 3/16

1/16

Fiberglass 1/8 3/16 1/8

Arrows, separation lines, and borders shall be the same depth and as shown in Figure 14-7. After routing, sand all surfaces with a fine grit (100+) sandpaper.

Wipe all surfaces and lettering clean.

1/16- to 1/4-in. deep

1/4 in.

Square cut detail Routed separation line on AS, RS, RSE, and NRA-REC signs

Outside border detail Shield, recreation symbols, credits

1/16- to 1/4-in. deep Varies (per specifications)

Figure 14-7—Routing details.

14-18

December 2005

14.8 Finishing Operations

The entire sign (face, back, edges, and routed areas) shall be finished as specified in procurement documents and as shown in drawings.

Medium-Density Overlay (MDO) plywood substrate signs – All MDO plywood signs shall be painted. Scuff-sand the MDO plywood with a fine grit sandpaper to slightly roughen the surface. Apply one coat of primer and two coats of paint of the specified color precisely as prescribed in writing by the manufacturers of the primer and paint.

Lumber substrate signs – Lumber signs shall be stained or painted, as specified. Painting shall be as described for MDO plywood substrate signs above. Signs specified to be stained shall receive two coats of stain applied precisely as prescribed in writing by the manufacturer of the stain.

Dipped-in-stain oak signs – When specified, solid oak routed-wood signs shall be dipped in a transparent stain with UV inhibitors and water repellent characteristics. (i.e., Super Deck Brand DB 1910-Natural). Signs shall be left in the stain for a minimum of 3 hours to allow penetration into the wood. When removed from the dip, excess stain shall be wiped off. This stain protects the white oak from weathering and turning gray.

Artificial weathering (lumber) – When specified, trail signs shall be artificially weathered by wire-brushing with the grain or by sandblasting to a depth of approximately 1/32 inch, followed by two coats of the specified stain applied precisely as specified in writing by the manufacturer of the stain.

Unfinished signs – When specified, lumber signs shall be left unfinished.

Blackened or scorching – When specified, all routing shall be painted black or scorched black. Substrate surface shall be lightly sanded to remove any blackening or scorching outside routed areas.

14.9. Maker’s Mark

A decal showing the contractor’s identification or trademark and the date of manufacture shall be installed on the back, lower left-hand corner of each sign manufactured or for diamond shaped signs, on the left corner. For lumber signs, this information shall be stamped on the back, lower left-hand corner or edge of the sign panel. Decals with this information may be applied to signs manufactured with fiberglass, aluminum, or HDO substrates. On plastic banner signs, the mark shall be applied to only one side in the upper left-hand corner of the sign.

14.10 Materials Certification

All materials used in the manufacture of signs shall comply with the requirements of these specifications. It is the responsibility of the sign manufacturer (contractor) to obtain and, if requested, furnish to the contracting officer, certification that all materials comply with the requirements as specified.

14-19

December 2005

14.11 Packaging and Shipping

14.11.1 Packaging

Signs shall be packaged so that sign surfaces and edges are protected from damage during shipping.

After packaging the sign, the contractor shall place a copy of the sign requisition and all other documents and certifications requested in a heavily constructed envelope and attach it securely to the package.

14.11.2 Shipping

Signs shall be shipped to the designated location and in conformance with procedures designated in the contract.

14.11.3 Receiving Inspection

Prior to acceptance by the ordering unit, and within 10 working days of receipt of finished signs, the ordering unit shall inspect the signs for compliance with the specifications.

14.12 Method of Measurement

Signs, completed and accepted, shall be measured either by the square foot of surface area (nearest one-half square foot), or on an individual unit basis as shown in procurement documents.

14.13 Basis of Payment

The quantities shall be paid for at the contract price per unit of measurement for each pay item listed. The payment shall be full compensation to the contractor for all materials and sign fabrication, including all labor, equipment, tools, and incidentals needed; payment includes shipping costs when so specified in the contract.

14.14 Sign-Blank Standards

The following sign-blank standards illustrate how to construct the substrates for the various signs used by the Forest Service.

14-20

December 2005

H1

L1

L2

H2

X

R1

R2 R2

R3

Blank standard—National Forest Entrance (FE) Administrative Site Identification signs (AS) National Recreation Area Forest Boundary Entrance sign (NRS-E)

Dimensions (inches)

Sign number H1 L1 X L2 H2 R1 R2 R3

3 36 54 9 49 27 1/2 4 6 5

4 48 72 12 65 1/4 36 1/2 5 9 7

5 60 90 15 81 1/2 45 1/2 6 10 9

6 72 108 18 97 3/4 54 1/2 7 12 10

7 84 126 21 114 63 1/2 9 14 12

8 96 144 24 130 1/2 72 1/2 10 16 14

14-21

December 2005

Blank standard—Minor Forest Entrance (MFE), Minor Forest Leaving (MFL), and National Forest Land (NFL) signs

H1

L1

L2

M1

M2

3/8-inch mounting holes typical 2 places

H2

X

R typical

L2

Dimensions ( )

Sign number H1&L1 X L2 H2 M1 M2 R

MFE/MFL/NFL-18 18 3 3/4 15 15 1 15 2

MFE/MFL/NFL-27 27 5 3/4 22 1/4 22 1/4 1 3/4 22 3/4 3

Note:

All mounting holes are 3/8-inch diameter.

14-22

December 2005

Blank standard—USDA Credit Line #1 (P)

H

1/8- to 3/16-inch radius typical each corner

X L

Dimensions (inches)

Sign number H L X

P-37 3 1/2 37 1 3/8

P-43 5 1/2 43 2

P-52 5 1/2 52 2

P-56 5 1/2 56 2

P-68 6 1/2 68 2 3/8

P-80 6 1/2 80 2 3/8

P-95 7 1/2 95 2 3/4

P-110 7 1/2 110 2 3/4

1/8- to 3/16-inch radius typical each corner

H

L

Dimensions (inches)

Sign number H L

P-37 3 1/2 37

P-43 5 1/2 43

P-52 5 1/2 52

P-56 5 1/2 56

P-68 6 1/2 68

P-80 6 1/2 80

P-95 7 1/2 95

P-110 7 1/2 110

Blank standard—USDA Optional Credit Line #1 (P)

14-23

December 2005

Blank standard—Forest/District Administrative Site sign (A) for urban location

H

R typical all corners

L

Dimensions (inches)

Sign number H L X

A3 18 34 1/2

A5 30 54 1 1/2

A7 46 94 2

14-24

December 2005

Blank standard—Recreation Site Identification sign (RS)

H1

L1

L2 X

R typical

Dimensions (inches)

Sign number H L1 X L2 R

RS-1 30 48 6 42 6

RS-2 40 63 8 55 7

RS-3 48 78 9 1/4 68 3/4 8

RS-4 60 93 11 1/2 81 1/2 9

14-25

December 2005

Blank standard—Optional Recreation Site Identification sign (RSE)

H1

L1

L2 X

R typical

Dimensions (inches)

Sign number H L1 X L2 R

RSE-1 14 30 2 28 2 1/2

RSE-2 20 48 4 44 3

RSE-3 24 60 4 3/4 55 1/4 4

RSE-4 28 72 5 1/2 66 1/2 5

14-26

December 2005

Blank standard—Site Approach sign (SA)

H1 M2

M1

L1

L2 M4

X M3

R typical

3/8-inch mounting holes typical 4 places

Dimensions (inches)

Sign number H L1 X L2 M1 M2 M3 M4 R

SA-1 40 38 5 33 2 36 8 22 4

SA-2 52 48 6 1/2 41 1/2 3 46 10 28 5

14-27

December 2005

H

L1

L2 X

R typical

Dimensions (inches)

Sign number H L1 X L2 R

2 24 30 4 1/2 25 1/2 4

3 36 48 7 41 6

4 48 63 9 1/2 53 1/2 7

5 60 78 11 1/2 66 1/2 9

6 72 93 14 79 10

7 84 108 16 92 12

8 96 126 18 1/2 107 1/2 14

Blank standard—interpretative signs such as National Recreation Area (NRA) National Volcanic Monument (NVM) 5-line Recreation Entrance

14-28

December 2005

Blank standard—route markers (FM1-7H)

H

A

A R typical

L L2

3/8-inch mounting holes typical 2 places

Dimensions (inches)

Sign number H L A R

FM1-7H-16 8 16 1 1 1/2

FM1-7H-21 8 21 1 1 1/2

FM1-7H-20 10 20 1 1 1/2

FM1-7H-28 10 28 1 1 1/2

FM1-7H-26 12 26 1 1 1/2

FM1-7H-36 12 36 1 1 1/2

14-29

December 2005

Blank standard—National Recreation Area USDA Credit Line 2 (NRA-P)

H

L

R typical

Dimensions (inches)

Sign number H L R Fits panel sizes

NRA-P10 10 Variable 1 1/2 Up to 63

NRA-P12 12 Variable 1 1/2 78 and larger

Note:

Mounting hole location is variable depending on type of mount.

14-30

December 2005

Blank standard—recreation symbol

H

L

M1

M2

Mounting holes typical 2 places

R typical

L2

Dimensions (inches)

Mount hole Sign number H&L M1 M2 R diameter

R-XXX-8 8 1 7 1 1/4 5/16

R-XXX-12 12 1 11 1 1/4 3/8

R-XXX-18 18 1 1/2 16 1/2 1 1/2 3/8

R-XXX-24 24 1 1/2 22 1/2 1 1/2 3/8

Note:

(XXX) specify sign number and series when ordering (see Chapter 7).

14-31

December 2005

Blank standard—Federal recreation symbols – Composite Recreation sign (CRS 16.2.1)

H

L

M

3/8-inch mounting holes typical 2 places

R typical

L2

Dimensions (inches)

Sign number H L M R

CRS-1 36 24 1 1

CRS-2 32 24 1 1 1/2

CRS-3 28 18 1 1 1/2

CRS-4 24 18 1 1/2 1 1/2

CRS-5 18 12 1 1/2 1 1/2

CRS-6 16 12 1 1/2 1 1/2

CRS-8 10 8 1 1/2 1 1/2

14-32

December 2005

Blank standard—Trail Destination sign (TD)

H

R typical

L L2

M

3/8-inch mounting holes typical 2 places

M

Dimensions (inches)

Sign number H L M R

TD-1 5 Varies 1 1/2

TD-2 7 Varies 1 1/2

TD-3 9 Varies 1 1/2

TD-4 11 Varies 1 1/2

TD-5 13 Varies 1 1/2

14-33

December 2005

Blank standard—Trail Blazer sign (TB)

H

H2 M

Mounting holes typical 2 places

M

R typical L

L2

Dimensions (inches)

Mounting Sign number H L M hole diameter R

TB-1 7 5 2 1/2 1/8 3/8

TB-2 12 9 4 1/2 1/4 1/2

14-34

December 2005

Blank standard—Wilderness/Primitive Area Entrance signs (horizontal) (WPH)

H1 H2

L1

L2

H3

X

R2

R1 R1

R1

R3

B

Dimensions (inches)

Sign number H1 L1 H2 B H3 X L2 R1 R2 R3

WPH-40-L or R 20 40 16 12 15 4 37 1/2 2 3 6

WPH-60-L or R 30 60 25 18 22 6 56 4 5 12

14-35

December 2005

Blank standard—Wilderness/Primitive Area Entrance signs (vertical) (WPV)

H1

H2

H2

H4

L Y

R2

R1

R1 R1

R1

X

Dimensions (inches)

Sign number H1 L H2 Y H3 H4 X R1 R2

WPV-18-L or R 18 13 11 1 3/4 15 1/2 1/2 2 3/4 2 2 1/2

WPV-36-L or R 36 24 22 3 1/2 31 1 5 4 5

14-36

December 2005

Blank standard—Wilderness/Primitive Area USDA Credit Line (WP-PV and WP-PH)

1/8- to 3/16-inch radius typical each corner

H

L

Dimensions (inches)

Sign number H L

WP-PV 3 22

WP-Ph 3 1/2 42

14-37

December 2005

Blank standard—National Wild and Scenic River logo (WSR)

H

H2 M

Mounting holes typical 2 places

M

R typical L

L2

Dimensions (inches)

Mount hole Sign number H L M R diameter

WSR-2 18 15 1/2 7 1/2 17 3/8

WSR-3 9 7 3/4 3 1/2 8 1/2 1/4

WSR-4 3 1/2 3 1 3/8 3 1/4 1/8

14-38

December 2005

Blank standard—STOP (FRI-1) and YIELD (FRI-2) signs

H1 M2 H2

X M1

X

3/8-inch mounting holes typical 2 places

L

Dimensions (inches)

Sign number H1&L X H2 M1 M2

FR1-1-12 12 1 1/2 3 1/2 8 1/2 9

FR1-1-18 18 3 5 1/4 12 3/4 12

FR1-1-24 24 3 7 17 18

FR1-1-30 30 3 8 3/4 21 1/4 24

M2 H

M1

3/8-inch mounting holes typical 2 places

L

Dimensions (inches)

Sign number H&L M1 M2 R

FR1-2-18 18 2 10 1

14-39

December 2005

H

L

Mounting holes typical 2 places

R typical

L2

M

M

Dimensions (inches)

Sign number H L M R

FR-11-3A 18 30 1 1/2 1 1/2

FR-4-2B 12 18 1 1/2 1 1/2

H

L

3/8-inch mounting holes typical 4 places

R typical

L2

M2 M2 M

M

Dimensions (inches)

Sign number H L M1 M2 R

FR-13-1A 18 48 1 1/2 12 1 1/2

FR-13-1B 18 38 1 1/2 12 1 1/2

FR-13-1C 18 38 1 1/2 15 1 1/2

FR-8-1A-24 24 48 1 1/2 15 1 1/2

FG-20-3 (42”) 24 42 1 1/2 13 1 1/2

FG-20-3 (60”) 30 60 1 1/2 18 1 1/2

Blank standard—regulatory signs (FR) warning signs (FW)

14-40

December 2005

Blank standard—warning/construction sign (FW)

L

M

3/8-inch mounting holes typical 2 places

L

M

R typical

Dimensions (inches)

Sign number L M R

FW-12 12 5 1 1/2

FW-18 18 8 1 1/2

FW-24 24 12 1 1/2

FW-30 30 15 1 7/8

14-41

December 2005

Blank standard—barricade marker (BM) object marker (OM)

H

H2

L

M

Mounting holes typical 2 places

M

3/16- to 1/4-inch typical all corners

Dimensions (inches)

Sign number H L M

BM-8 8 24 3

BM-12 12 36 3

L2 L

H

M

Mounting holes typical 2 places

M

3/16- to 1/4-inch typical all corners

Dimensions (inches)

Sign number H L M

OM-6x12 12 6 1 1/2

OM-8x24 24 8 3

OM-12x36 36 12 3

14-42

December 2005

Blank standard—Forest Route marker (M1-7)

H M2

M1

3/8-inch mounting holes typical 2 places

L

Dimensions (inches)

Sign number H&L M1 M2

M1-7-18 18 1 1/2 16 1/2

M1-7-24 24 1 1/2 22 1/2

Note:

See Standard Highway Signs, page 3-8 for blank standard dimensions other than mounting hold information shown here.

14-43

December 2005

Blank standard—Forest Road Destination sign (FRD)

H

R typical

Typical single-post detail

L L2

M

3/8-inch mounting holes typical 2 places

M

Dimensions (inches)

Sign number H L (up to 36) M R

FRD Varies Varies 1 1/2 1 1/2

H

R typical

Typical two-post detail

L 1/5L

M

3/8-inch mounting holes typical 4 places

M

1/5L

3/5L

H

R typical

Typical three-post detail

L L2

M

3/8-inch mounting holes typical 6 places

M

1/8L

Dimensions (inches)

Sign number H L (73 to 96) M R

FRD Varies 73 to 96 1 1/2 to 3 1 1/2

Dimensions (inches)

Sign number H L (37 to 72) M R

FRD Varies 37 to 72 1 1/2 to 3 1 1/2

14-44

December 2005

Blank standard—Scenic Byway Logo (SBL)

H

L

M

M

3/8-inch mounting holes typical 2 places

R typical

L2

Dimensions (inches)

Sign number H&L M R

SBL-1 18 1 1/2 1 1/2

SBL-2 24 1 1/2 1 1/2

SBL-3 30 1 1/2 1 1/2

14-45

December 2005

Blank standard—hinged sign

Front of sign when open

Back of sign when open

Closed sign

Hidden piano hinge

Screw

Piano hinge

Hinged sign on HDO substrate

Note: provide device to hold sign closed/open.

Sign open

Sign closed