Refer to: HSA-10/WZ-100 Amendment #3

Mr. Bill Korman
Korman Signs, Incorporated
3029 Lincoln Avenue
Richmond, VA 23228

Dear Mr. Korman:

This is in response to your letters of April 17 and June 16, 2003, requesting Federal Highway Administration (FHWA) acceptance of variations to a number of your company's portable sign stands as crashworthy traffic control devices for use in work zones on the National Highway System (NHS). Accompanying your letter were descriptions and drawings of the devices, and references to the crash tests you believe substantiate your requests. You asked that we find these devices acceptable for use on the NHS under the provisions of National Cooperative Highway Research Program (NCHRP) Report 350 "Recommended Procedures for the Safety Performance Evaluation of Highway Features." As many of the stands are already covered under FHWA Acceptance Letter WZ-100, originally issued on June 20, 2002, WZ-100, Amendment #1, dated January 23, 2003, and Amendment #2, dated April 21, 2003, you asked that we consider this a request to amend WZ-100 with the updated information.

Introduction
The FHWA guidance on crash testing of work zone traffic control devices is contained in two memoranda. The first, dated July 25, 1997, titled "INFORMATION: Identifying Acceptable Highway Safety Features," established four categories of work zone devices: Category I devices were those lightweight devices which could be self-certified by the vendor, Category II devices were other lightweight devices which needed individual crash testing, Category III devices were barriers and other fixed or massive devices also needing crash testing, and Category IV devices were trailer mounted lighted signs, arrow panels, etc. The second guidance memorandum was issued on August 28, 1998, and is titled "INFORMATION: Crash Tested Work Zone Traffic Control Devices." This later memorandum lists devices that are acceptable under Categories I, II, and III.

brief description of your requests, including designation of the sign stands and the sizes and substrates you wish to use follows.

The purpose of Request #1 is to clarify the intent of WZ-100 Request which was to accept the use of up to 25 square feet of Alpolic ® 350 sign or combination of signs mounted directly to the rails of any NCHRP Report 350 accepted Type III barricade and be more specific about the physical mounting height limitations.

The purpose of Request #2 is to alter the SS560E and SS560AE stands so that they may accommodate 84" mounting heights as well as the previously accepted 60" height. The upper mast is 15" longer to allow this taller placement.

The purpose of Request #3 is to alter the SS548E and SS548AE stands so that they can accommodate Alpolic ® 350 and 0.100 Aluminum signs at 60 inches. They have been tested at 19 and 21 inches with substrates from roll ups to rigid. The SS560 sign stand family has also been tested with solid aluminum signs mounted at 60 inches (where the sign detaches and goes over the vehicle.) Unmodified, they can accommodate a rollup sign by attaching the vertical fiberglass spreader to the top of the mast. Your request is to extend the upright and add a mounting bracket so that this stand can accommodate signs at the 60 inch mounting height in addition to the 19 to 21 inch mounting heights.

The purpose of Request #4 is to allow the use of the SS560, SS560A, SS560E, and SS560AE stands with the rollup signs at 84 inches simply by raising the pivot point of the fiberglass spreaders to the top of the mast, rather than having the top of the sign affixed to the top of the mast. The upper portion of the mast will separate from the stand and pass over the vehicle.

The purpose of Request # 5 is to include the warning light that was recently tested and was found to perform acceptably. During the tests, (impacts 103A and 103B) the lights detached shortly after impact and passed harmlessly over the vehicle.

The purpose of Request #6 is to broaden the acceptance of the Korman Type III barricade from the original configuration (impacts 2A, 3B, 58A, 59B, 60A) to a wider range of heights, widths, and sign mountings tested recently (impacts 101A, 101B, 102A, 104B, and 105A.) The tests, summarized below, did not result in any penetration of the windshield.

Length: 8 feet  Height: 5 feet, Plastic Rails: No windshield damage
Length: 8 feet  Height: 5 feet, Alpolic
Rails: No windshield contact Length: 12 feet   Height: 7 feet, Plastic Rails: Moderate cracking Length: 12 feet   Height: 5 feet, Plastic Rails: Moderate cracking

The 12 foot long, 5 foot high barricade replicates the general design of the barricade tested for the Michigan Department of Transportation (MDOT) that failed using wood rails. The testing conducted for MDOT impacted the device head on and at an angle of 90 degrees. As the head-on test was the one that failed, the Korman Type III 12 foot x 5 foot barricade was tested head on with successful results. Note that heights between 5 and 7 feet should be avoided.

The following enclosures detail the sign and barricade designs, plus summarize the requested changes and the crash testing that has been done to support the requests.

Enclosure 1 is a drawing showing the clarifications of sign sizes and placement on Type III Barricades.
Enclosure 2 is a SS560EE drawing showing the 84" mounting height for rigid signs.
Enclosure 3 is a SS560EE drawing showing the 84" mounting height for rollup signs.
Enclosure 4 is a SS560AEE drawing showing the 84" mounting height for rigid signs.
Enclosure 5 is a SS560AEE drawing showing the 84" mounting height for rollup signs.
Enclosure 6 is a SS548EE drawing showing the 60" mounting height for rigid signs.
(60" mounting height accepted by WZ-100, Request 3 for Roll Up Signs)
Enclosure 7 is a SS548AEE drawing showing the 60" mounting height for rigid signs.
(60" mounting height accepted by WZ-100, Request 3 for Roll Up Signs)
Enclosure 8 is a SS560 drawing showing the 84" mounting height for rollup signs.
Enclosure 9 is a SS560A drawing showing the 84" mounting height for rollup signs.
Enclosure 10 is a SS560E drawing showing the 84" mounting height for rollup signs.
Enclosure 11 is a SS560AE drawing showing the 84" mounting height for rollup signs.
Enclosure 12 is an updated product description and glossary summarizing the additional items.
Enclosure 13 is a Summary of Requests Chart.
Enclosure 14 is a Summary of Accepted Devices Chart.
Enclosure 15 is a drawing showing the construction details of Model WBT3 Type III barricades and clarifications of sign sizes and placement.
Enclosure 16 is a SS1 drawing showing the stand with a light attached.
Enclosure 17 is a summary of crash tests conducted.
Enclosure 18 is a drawing of the light bracket for barricades.
Enclosure 19 is a drawing of the light bracket for the SS1 tripod sign stand.

Findings
We concur in your requests as they are based on current testing, prior testing, or logical extrapolation. Therefore, the devices described in the various requests above and detailed in the enclosed tables and drawings are acceptable for use on the NHS under the range of conditions tested, when proposed by a State. Please note that Enclosure #14 summarizes all acceptable sign stands that were accepted by WZ-100 and this Amendment and all prior Amendments.

Please note the following standard provisions that apply to FHWA letters of acceptance:

• Our acceptance is limited to the crashworthiness characteristics of the devices and does not cover their structural features, nor conformity with the Manual on Uniform Traffic Control Devices.
• Any changes that may adversely influence the crashworthiness of the device will require a new acceptance letter.
• Should the FHWA discover that the qualification testing was flawed, that in-service performance reveals unacceptable safety problems, or that the device being marketed is significantly different from the version that was crash tested, it reserves the right to modify or revoke its acceptance.
• You will be expected to supply potential users with sufficient information on design and installation requirements to ensure proper performance.
• You will be expected to certify to potential users that the hardware furnished has essentially the same chemistry, mechanical properties, and geometry as that submitted for acceptance, and that they will meet the crashworthiness requirements of FHWA and NCHRP Report 350.
• To prevent misunderstanding by others, this letter of acceptance, designated as number WZ-100 Amendment #3 shall not be reproduced except in full. This letter, and the test documentation upon which this letter is based, is public information. All such letters and documentation may be reviewed at our office upon request.

The Korman sign stands may include patented components and if so are considered "proprietary." The use of proprietary work zone traffic control devices in Federal-aid projects is generally of a temporary nature. They are selected by the contractor for use as needed and removed upon completion of the project. Under such conditions they can be presumed to meet requirement "a" given below for the use of proprietary products on Federal-aid projects. On the other hand, if proprietary devices are specified for use on Federal-aid projects, except exempt, non-NHS projects, they: (a) must be supplied through competitive bidding with equally suitable unpatented items; (b) the highway agency must certify that they are essential for synchronization with existing highway facilities or that no equally suitable alternative exists or; (c) they must be used for research or for a distinctive type of construction on relatively short sections of road for experimental purposes. Our regulations concerning proprietary products are contained in Title 23, Code of Federal Regulations, Section 635.411, a copy of which is enclosed.

Sincerely yours,

Michael S. Griffith
Acting Director, Office of Safety Design
Office of Safety

Enclosures