sign design, fabrication & patterns

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2OntarioTrafficManual

March 2005

Sign Design,Fabrication & Patterns

Book 2 • Sign Design, Fabrication and Patterns

Ontario Traffic Manual • March 2005 1

OntarioTraffic Manual

Foreword

The purpose of the Ontario Traffic Manual (OTM)is to provide information and guidance fortransportation practitioners and to promoteuniformity of treatment in the design, applicationand operation of traffic control devices and systemsacross Ontario. The objective is safe drivingbehaviour, achieved by a predictable roadwayenvironment through the consistent, appropriateapplication of traffic control devices. Furtherpurposes of the OTM are to provide a set ofguidelines consistent with the intent of the HighwayTraffic Act and to provide a basis for roadauthorities to generate or update their ownguidelines and standards.

The OTM is made up of a number of Books, whichare being generated over a period of time, and forwhich a process of continuous updating is planned.Through the updating process, it is proposed thatthe OTM will become more comprehensive andrepresentative by including many traffic controldevices and applications appropriate for municipaluse, in addition to those for highway use. Some ofthe Books of the OTM are new, while othersincorporate updated material from the OntarioManual of Uniform Traffic Control Devices (MUTCD)and the King’s Highway Guide Signing PolicyManual (KHGSPM).

The Ontario Traffic Manual is directed to its primaryusers, traffic practitioners. Book 2 is an exception,being directed at sign designers and fabricators.The OTM incorporates current best practices in theProvince of Ontario. The interpretations,recommendations and guidelines in the OntarioTraffic Manual are intended to provide anunderstanding of traffic operations and they cover abroad range of traffic situations encountered inpractice. They are based on many factors whichmay determine the specific design and operationaleffectiveness of traffic control systems. However, nomanual can cover all contingencies or all casesencountered in the field. Therefore, field experienceand knowledge of application are essential indeciding what to do in the absence of specificdirection from the Manual itself and in overridingany recommendations in this Manual.

The traffic practitioner’s fundamental responsibilityis to exercise engineering judgement andexperience on technical matters in the bestinterests of the public and workers. Guidelines areprovided in the OTM to assist in making thosejudgements, but they should not be used as asubstitute for judgement.

Design, application and operational guidelines andprocedures should be used with judicious care andproper consideration of the prevailingcircumstances. In some designs, applications, oroperational features, the traffic practitioner’sjudgement is to meet or exceed a guideline while inothers a guideline might not be met for soundreasons, such as space availability, yet still producea design or operation which may be judged to besafe. Every effort should be made to stay as closeto the guidelines as possible in situations like these,to document reasons for departures from them, andto maintain consistency of design so as not toviolate driver expectations.

The specific purpose of Book 2 is to providepractical guidelines and sign patterns for the designand fabrication of traffic signs.



Custodial Office

Inquiries about amendments, suggestions orcomments regarding the Ontario Traffic Manualmay be directed to:

Ontario Traffic Manual CommitteeMinistry of TransportationOntario Traffic Office301 St. Paul Street, 2nd FloorSt. Catharines, ON L2R 7R4tel: (905) 704-2960fax: (905) 704-2888e-mail: [email protected]

A user response form is provided at the end of OTMBook 1. Inquiries regarding the purchase anddistribution of this Manual may be directed to thecustodial office, or to:

Publications Ontario880 Bay StreetToronto, ON M7A 1N8tel: (416) 326-5300 or

1-800-668-9938TTY: 1-800-268-7095Fax: (613) 566-2234web: www.publications.gov.on.ca

Book 2 (Sign Design, Fabrication and Patterns) andits associated Book 2 Training Work Book for signdesigners and manufacturers were developed withthe assistance of a Stakeholder AdvisoryCommittee organized by the Ministry ofTransportation.

Project Consultant Team

Milton Harmelink, Dillon Consulting LimitedRodney Edwards, Harpar Management CorporationClaudio Covelli, Dillon Consulting LimitedRick Glenn, JR ConsultingMaryAnn Lovicsek, IBI GroupAlison Smiley, Human Factors NorthBetty Scott, Betty Scott & Associates

Design and Production

Suzanne Rodenkirchen, Green LeafCommunications (Book 2 & TrainingWork Book)

Kelli Carder, Harpar Management Corporation(Master Sign Library)

John Paul Atherton, Graphic Artist (Illustrations,Training Work Book)

Stakeholder Advisory Committee

Robert Barr, Ontario Traffic Conference (OTC),City of Guelph

Chris Blackwood, Transportation Association ofCanada (TAC)

Tim Burns, Ministry of Transportation Ontario(SW Region Traffic)

Gerry Chaput, Ministry of Transportation Ontario(Traffic Office)

Anthony Ching, Municipal Engineers Association(MEA), City of Vaughan

Joe Colafranceschi, City of TorontoSandy De Lorenzi, Ministry of Transportation

Ontario (Central Region Traffic)Tracey Difede, Ministry of Transportation Ontario

(Traffic Office)Harold Doyle, Ministry of Transportation Ontario

(Traffic Office)Yoassry Elzohairy, Ministry of Transportation Ontario

(Traffic Office)Ron Haslam, Scugog SignsMazda Hodiwala, Ministry of Transportation Ontario

(Traffic Office)George Karlos, Ministry of Transportation Ontario

(Traffic Office)John Kerfoot, Ontario Good Roads Association

(OGRA), Region of WaterlooCathy Robertson, Institute of Transportation

Engineers (ITE), Town of OakvilleKevin Smith, Owl-liteRichard Sturge, Ministry of Transportation Ontario

(Provincial Sign Shop)



Table of Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Purpose, Scope and Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Sign Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.4 Metrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.5 Bilingual and French Language Sign Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Guidelines for Sign Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1 Standardization of Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2 Approaches to Sign Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Driver Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.4 Shape and Colour Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5 Text Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5.1 Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5.2 Letter Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.5.3 Upper and Mixed Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.5.4 Horizontal Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6 Symbolic Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.6.1 Arrow Type and Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.6.2 Interdictory and Permissive Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.6.3 Logo Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.7 Calculating Letter Height and Symbol Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.7.1 Reading Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.7.2 Decision Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.7.3 Manoeuvre Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.7.4 Required Legibility Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7.5 Minimum Letter Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.7.6 Symbol Legibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.7.7 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


Ontario Traffic Manual • March 20054

2.8 Sign Design Elements and Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.8.1 Message Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.8.2 Interline Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.8.3 Border Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.9 Reflectorization and Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.9.1 Retroreflective Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.9.2 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.10 Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.10.1 Positive Contrast Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.10.2 Negative Contrast Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.11 Selecting the Sign Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.12 Bilingual Sign Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.13 Process for Assessing and Revising Sign Designs . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.13.1 Comprehension Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.14 Sign Design Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.14.1 Standard Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.14.2 Customized Standard Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Style of Lettering and Legend Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Letter Size: Metric to Imperial Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Limits on Destination Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Symbols, Crowns, Shields, Markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Centring and Justification Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Sign Border Sizing and Cornering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Size of Guide Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Overhead Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Differences between Overhead and Ground-mounted Signs . . . . . . . . . . . . . . . 57

2.14.3 Diagrammatic Guide Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Usage Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Usage not Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Design Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.14.4 Non-standard Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59



2.15 Sign Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.15.1 Sign Design Process Flowchart (Flowchart A) . . . . . . . . . . . . . . . . . . . . . . . 60

2.15.2 Application of Sign Design Process (Selected examples) . . . . . . . . . . . . . . . . . . 65

3. Sign Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.1 Sign Face Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.1.1 Types of Sign Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.1.2 Sheeting Standards and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.1.3 Screen Printing Ink and Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.2 Sign Sheeting Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.2.1 Durability and Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.2.2 Benefit/Cost Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

3.3 Sign Substrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.3.1 Substrate Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Plywood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Extruded Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Other Substrate Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.3.2 Standards and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4. Sign Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.1 Substrate Preparation, Testing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.1.1 Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.1.2 Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.1.3 Plywood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.1.4 Extruded Aluminum Panels and Aluminum Overlay Sheets . . . . . . . . . . . . . . . . 90

4.1.5 Other Substrate Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Plastic/Fibreglass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Recycled Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.1.6 Random Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.1.7 Storage of Substrates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.2 Background Sheeting Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.2.1 Pressure Sensitive Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Mechanical Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93



Hand Squeeze Roll Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Hand (Squeegee) Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.2.2 Heat-activated Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.3 Sign Assembly (Extruded Aluminum Panels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.3.1 Bolt-together Panels and Snap-together Panels . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.3.2 Aluminum Overlay Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.4 Legend Preparation and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.4.1 Screen Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.4.2 Direct-applied Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Hand-cut Copy or Individually Cut Legend Characters . . . . . . . . . . . . . . . . . . . . 103

Computer-cut Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Reverse-cut Transparent Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.5 Storage of Partially Completed and Completed Signs . . . . . . . . . . . . . . . . . . . . . 108

4.6 Sign Fabrication Process (flowcharts & procedures) . . . . . . . . . . . . . . . . . . . . . . . 108

Flowchart B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

B.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

B.2 Metal Blank Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

B.3 Plywood Blank Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

B.4 Extruded Aluminum Panel Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

B.5 Aluminum Overlay Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

B.6 Background Sheeting Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

B.7 Legend Application: Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

B.7A Construction of a Screen Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

B.8 Legend Application: Direct-applied Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

B.9 Extruded Aluminum Sign Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

5. Master Sign Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.1 Master Sign Library Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.1.1 Sign Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.1.2 Sign Pattern Template (SPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.1.3 Electronic Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Adobe® Illustrator® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Adobe® Acrobat® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5.1.4 Sign Parts Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122



5.1.5 Sign Blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5.1.6 CD-ROM Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

5.2 Use of the Master Sign Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.2.1 Standard Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.2.2 Customized Standard Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Appendix A • Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Appendix B • References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

List of Tables

Table 1.1 Comparison of Old and New Sign Numbering Systems . . . . . . . . . . . . . . . 13

Table 2.1 Shape and Colour Codes for Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 2.2 Shape and Function of Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 2.3 Lane Change Manoeuvre Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 2.4 Legibility-Distance-to-Letter-Height Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 2.5 Acceptable Sign Colour Combinations Based on Brightness Contrast . . . 33

Table 2.6 Factors Affecting Detailed Sign Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Table 2.7 Letter Sizes for Freeway Directional Guide Signs . . . . . . . . . . . . . . . . . . . . . 40

Table 2.8 Letter Sizes for Non-freeway Directional Guide Signs . . . . . . . . . . . . . . . . . 40

Table 2.9 Suppliers of Sign-making Equipment and Software . . . . . . . . . . . . . . . . . . . 42

Table 2.10 Imperial to Metric Conversion Chart for Letter Heights . . . . . . . . . . . . . . . . 44

Table 2.11 Use of Arrows on Advance and Exit Guide Signs . . . . . . . . . . . . . . . . . . . . . 50

Table 2.12 Sign Border and Cornering Dimensions: Metal Blanks . . . . . . . . . . . . . . . . 54

Table 2.13 Sign Border and Cornering Dimensions: Plywood Blanks . . . . . . . . . . . . . . 54

Table 2.14 Sign Border and Cornering Dimensions: Aluminum Extrusion . . . . . . . . . . 54

Table 2.15 Standard Print Colour Specifications for Ontario Traffic Signs . . . . . . . . . . 56

Table 3.1 Types of Retroreflective Sheeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Table 3.2 ASTM R-Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Table 3.3 Sign Sheeting Service Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Table 3.4 Standards and Specifications for Sign Substrate Materials . . . . . . . . . . . . . 87

Table 3.5 OPSS-specified Substrate Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Table 5.1 MTO Standard Sign Blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124



List of Figures

Figure 2.1 Example of FHWA Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Figure 2.2 Example Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 2.3 Spacing Guidelines for Text on Directional Guide Signs . . . . . . . . . . . . . . . 43

Figure 2.4 Spacing Guidelines for Text on Directional Guide Signswith Arrows, Crowns and Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Figure 2.5 Ahead Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 2.6 Parking Sign Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 2.7 Overhead Advance Sign Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Figure 2.8 Downward Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 2.9 Advance and Exit Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Figure 2.10 Examples of Diagrammatic Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Figure 2.11 Example: ADVANCE GUIDE Sign . . . . . . . . . . . . . . . . . . Gf-1 . . . . . . . . . . . 52

Figure 2.12 Example: DISTANCE ASSURANCE Sign . . . . . . . . . . . . Gf-12 . . . . . . . . . . 52

Figure 2.13 CHANNELIZING – RIGHT TURN Sign . . . . . . . . . . . . . . Gr-1 . . . . . . . . . . . 53

Figure 2.14 TURN OFF – RIGHT TURN Sign . . . . . . . . . . . . . . . . . . . Gr-2 . . . . . . . . . . . 53

Figure 2.15 CHANNELIZING – LEFT TURN Sign . . . . . . . . . . . . . . . Gr-3 . . . . . . . . . . . 53

Figure 2.16 TURN OFF – LEFT TURN Sign . . . . . . . . . . . . . . . . . . . . Gr-4 . . . . . . . . . . . 53

Figure 2.17 Sign Border and Corner Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Figure 2.18 Example of Diagrammatic Guide Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Figure 2.19 Standard Sign – MAXIMUM SPEED . . . . . . . . . . . . . . . Rb-1 . . . . . . . . . . 65

Figure 2.20 Standard Sign – MAXIMUM SPEED BEGINS . . . . . . . . Rb-2 . . . . . . . . . . 65

Figure 2.21 Customized Standard Sign – TURN-OFF RIGHT TURN Gr-2 . . . . . . . . . . . 66

Figure 2.22 Customized Standard Sign

– ADVANCE TURN-OFF RIGHT TURN . . . . . . . . . . . . . . Gf-22 . . . . . . . . . 68

Figure 2.23 Customized Standard Sign

– ADVANCE DESTINATION Tab . . . . . . . . . . . . . . . . . . . Gd-6A . . . . . . . . . 70

Figure 2.24 Diagrammatic Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Figure 3.1 Concept of Retroreflectivity using Glass Bead Technology . . . . . . . . . . . . . 75

Figure 3.2 Entrance Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Figure 3.3 Observation Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Figure 4.1 Snap-together Extruded Panel (cross-section) . . . . . . . . . . . . . . . . . . . . . . . . 91

Figure 4.2 Bolt-together Extruded Panel (cross-section) . . . . . . . . . . . . . . . . . . . . . . . . . 91

Figure 4.3 Mechanical Squeeze Roll Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Figure 4.4 Hand Squeeze Roll Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Figure 4.5 Mechanical Applicator Sheeting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 94



Figure 4.6 Application of Background Sheeting: Hand Squeeze Roll Applicator . . . . . 96

Figure 4.7 Snap-together Extruded Panels assembled with T-bars . . . . . . . . . . . . . . . . 98

Figure 4.8 Bolt-together Extruded Panels assembled with T-bars . . . . . . . . . . . . . . . . . 98

Figure 4.9 Extruded Panels assembled with Z-bar,for attachment to Trichord Sign Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Figure 4.10A Overlay Sheet on Extruded Panel Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Figure 4.10B Overlay Sheet on Extruded Panel Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Figure 4.11 Screen Printing Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Figure 4.12 Screen Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Figure 4.13 Drying Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Figure 4.14 Weeding Computer-cut Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 4.15 Transfer Tape Application to Sign Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 4.16 Taping of Legend and Transfer Tape to Sign . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 4.17 Removal of Backing from Sign Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 4.18 Legend Application to Sign Background with Hand Squeegee . . . . . . . . . 105

Figure 4.19 Removal of Transfer Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 4.20 Finished Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 4.21 Computer Cutting of Legend on Transparent Film . . . . . . . . . . . . . . . . . . . . 106

Figure 4.22 Weeding of Computer-cut Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Figure 4.23 Application of Transfer Tape to Reverse-cut Transparent Sheeting . . . . . . . 107

Figure 4.24 Positioning of Transfer Tape and Transparent Sheeting (with backing)

on Reflective White Background Sheeting on Substrate . . . . . . . . . . . . . . . 107

Figure 4.25 Stripping of Backing from Reverse-cut Transparent Sheeting (first half) . . . 107

Figure 4.26 Stripping of Backing from Reverse-cut Transparent Sheeting

(second half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Figure 4.27 Application of Transfer Tape and Reverse-cut Transparent

Sheeting to Reflective White Background Sheeting on Substrate . . . . . . . 107

Figure 4.28 Removal of Transfer Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Figure 4.29 Finished Sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Figure 5.1 Sign Pattern Template for Rb-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Figure 5.2 Sign Pattern Template for Gd-10B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

List of Flowcharts

Flowchart A.1 Sign Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Flowchart A.2 Sign Design Process – Customized Standard Sign Design . . . . . . . . . 62

Flowchart A.3 Sign Design Process – Standard Sign Design . . . . . . . . . . . . . . . . . . . 63



Flowchart A.4 Sign Design Process – Bilingual or French Language Signs . . . . . . . . 64

Flowchart B.1 Overview – Sign Fabrication Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Flowchart B.2 Metal Blank Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Flowchart B.3 Plywood Blank Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Flowchart B.4 Extruded Aluminum Panel Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 112

Flowchart B.5 Aluminum Overlay Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Flowchart B.6 Background Sheeting Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Flowchart B.7 Legend Application: Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Flowhchart B.7A Construction of a Screen Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Flowchart B.8 Legend Application: Direct-applied Copy . . . . . . . . . . . . . . . . . . . . . . . 117

Flowchart B.9 Extruded Aluminum Sign Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Electronic Master Sign Library (MSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD-ROM

Note: A Training Work Book is available separately. For more information, contact:

Ministry of TransportationTraffic Office301 St. Paul Street, 2nd FloorSt. Catharines, ON L2R 7R4tel: (905) 704-2960fax: (905) 704-2888e-mail: [email protected]

or

University of Toronto Press5201 Dufferin StreetToronto, ON M3H 5T8tel: (416) 667-8731 or

1-800-565-9523fax: (416) 667-7832 or

1-800-221-9985e-mail: [email protected]: http://www.utpress.utoronto.ca/



1. Introduction

1.1 Purpose, Scope, and Content

Book 2 (Sign Design, Fabrication and Patterns) ispart of a series of volumes that makes up theOntario Traffic Manual (OTM). Book 2 is intendedfor those engaged in the actual practice of signdesign and/or sign fabrication. Book 2 addressesthe design and fabrication of traffic signs andincludes a CD-ROM incorporating the electronicMaster Sign Library.

The Master Sign Library (MSL) contains theelectronic images of all signs in the various Booksof the OTM developed to date and of the relevantguide signs in Book 8 (under development, basedon the King’s Highway Guide Signing Policy Manual(KHGSPM)). These sign images are presentedaccording to a standard sign pattern template. Forstandard signs in OTM Books 5, 6, and 7, thesesign images are drawn to 1/10 scale and aresuitable for scaling up as appropriate to createactual full-size sign patterns for use in fabrication.For directional guide signs (Book 8/KHGSPM), thesign images are illustrative examples, but theycannot simply be scaled up as is, to create full sizesign patterns, as the legends on these signs needto be custom designed for specific locations.

The MSL also contains a Sign Parts Library of signelements, such as standard arrows, symbols, shieldsand markers, which need to be assembled by signdesigners in some cases, especially for customizedstandard directional and information guide signs.The MSL also contains a list of standard sign blanksand a set of patterns for standard metal sign blanks,including holes for mounting.

The scope of Book 2 includes the following:

• Sign design principles, incorporating much ofthe material in Book 1b (Sign Design Principles)for ready access and use by the sign designer,and for completeness of Book 2 as a stand-alonedocument. Rules and application guidelinesfor sign design, including procedures and a signdesign process flowchart, are also included.(Section 2)

• Sign materials (both sheeting and substrate)and selection criteria. (Section 3)

• Sign fabrication techniques, includingsubstrates, background sheeting, assembly, andlegend application. Application guidelines forsign fabrication, including procedures andprocess flowcharts, are also included. (Section 4)

• The approach taken in Book 2 with respect to theMaster Sign Library (including Sign PatternTemplate), and its elements, and applicationguidelines for use of the Master Sign Library.(Section 5)

• The electronic Master Sign Library, on a CD-ROMincluded as part of Book 2

Other Books in the OTM series provide practicalguidance on a full range of traffic control devicesand their application. A complete listing of theplanned and currently available volumes is found inBook 1, and an illustrated master index of signs andsignal displays is found in Book 1a (Illustrated Signand Signal Display Index).

The other OTM Books are aimed at the trafficpractitioner, and are not intended to providesufficient detailed information to design andfabricate individual signs. Book 2 on the other hand



is not aimed at the traffic practitioner, but isintended to provide sufficient information to signdesigners and manufacturers for the design andfabrication of individual signs.

Related to Book 2 are two Books yet to bedeveloped, Book 3 (Sign Support and Installation),and Book 4 (Sign and Delineation Maintenance).

With the exception of Book 2, the OTM Booksdepict symbolic and English language signs only.Book 2 contains all the symbolic and Englishlanguage signs, and also all standard Frenchlanguage and bilingual (English and French) signsdeveloped to date. Where French language orbilingual versions of standard signs are available,they have not been illustrated in the other OTMBooks, but are contained in the MSL as part ofBook 2.

New signs were not introduced in the developmentof Book 2. The approach taken in the OTM is thatnew signs, with their application policies, areintroduced where appropriate in the developmentand updating of the main policy Books, such asBooks 5, 6, 7, 8, and 9. Where so introduced, theMSL will need to be revised to include the signpatterns for any new signs adopted.

Other documents, not in the OTM series, are alsouseful. These are listed in Appendix B, References.

1.2 Sign Numbering System

The sign numbering system used in Book 2 and inthe Master Sign Library has been revised from thesystem used in the Ontario Traffic Manual Books 5,6, and 7, and in the King’s Highway Guide SigningPolicy Manual. The OTM Books 5, 6, and 7 usedthe sign numbering system of the Ontario MUTCD,with some minor revisions and renumbering.

The sign numbering system used for many years inthe MUTCD and the KHGSPM to distinguishstandard-size signs from oversize signs was asfollows:

• the standard-size sign almost always got the basicnumber designation (e.g., Ra-1) (there are a fewexceptions where a reduced-size sign had thebasic number designation, e.g., Rb-69 BICYCLEROUTE is reduced size, suitable for use on an off-road bicycle route, but not for use on a road; thefull-size sign for use on roads was given thedesignation Rb-169);

• the first oversize sign got a modified numberdesignation, by adding 100 to the basic signnumber (e.g., Ra-101);

• the second oversize (double oversize) sign got amodified number designation, by adding 1100 tothe basic sign number (e.g., Ra-1101).

The sign numbers themselves did not convey theactual sign sizes. These had to be obtained fromthe sign description in the OTM source Book (5, 6,or 7) or the KHGSPM, or from the sign template inthe MSL.

The revised sign numbering system now introducedinto the OTM, and used for the first time in Book 2,is based on the previous sign numbering system,but differs from it. The basic sign numbers areretained, but instead of a number indicating



SPT* Directory SPT Sign Title SPT Size Variants & Cut Images(1) (2) (3) & (4)

Ra-1 Ra-001 Ra-1 Ra-1 (0600 x 0600)Ra-101 Ra-001 Ra-1 Ra-1 (0750 x 0750)Ra-1101 Ra-001 Ra-1 Ra-1 (1200 x 1200)Rb-27 Rb-027 Rb-27 Rb-27 (0600 x 0750)Rb-127 Rb-027 Rb-27 Rb-27 (0900 x 1200)

Table 1.1 – Comparison of Old and New Sign Numbering Systems

Book 2 – New Numbering SystemOld NumberingSystem

* SPT = Sign Pattern Template

whether the sign is standard size, oversize, ordouble oversize, the actual dimensions of the signin millimetres are shown, along with a suffix: ‘B’ forbilingual signs or ‘F’ for French. If the standard signis English, symbolic, or considered understood inboth languages, no suffix is used. When Books 5, 6and 7 are next updated, their sign numberingsystem will be brought into conformance with thenew sign numbering system used in Book 2.

The sign numbering system used in the MasterSign Library (MSL) is the new numbering system,but with several slight variations. The main body ofthe MSL is made up of directories of Sign PatternTemplates (SPTs), one directory for each majorclassification of signs (regulatory, warning,temporary conditions, etc). Each SPT for aregulatory, warning, or temporary conditions signhas one or more cut images at 1/10 scale, whichare used to fabricate that sign for one or more sizes.The variations of the numbering system used forthe SPTs are as follows:

(1) The SPTs in the SPT directory are labelled bythe basic sign number, e.g., Ra-001 (This isthe Ra-1 sign, but a three-digit number isused to ensure that the signs within each signcategory (e.g., Ra) are listed in truealphanumeric order).

(2) Each SPT has the basic sign number (e.g.,Ra-1) displayed in the upper right part of thetitle bar at the top.

(3) Each SPT has listed on it, in the parameterblocks below the depicted sign pattern, theavailable sizes for that sign. The sign numberused for each of these variations is the basesign number together with the sign size inparentheses (e.g., Ra-1 (0600 x 0600)).

(4) Finally, for each available sign size, a 1/10scale cut image of the sign is attached to theSPT. The sign number used for the cut imagewill match the sign number in (3) (e.g., Ra-1(0600 x 0600)). Note that although the SPTsfor directional guide signs also have a 1/10scale sign image, it is illustrative only, and isnot intended to be a cut image for fabrication.

A comparison example of the old and newnumbering system is as shown in Table 1.1(Numbers in parentheses in the column headingsrefer to the numbered points directly above).



1.3 Revisions

As established at the outset of the OTMdevelopment, the concept of the OTM is to have aseries of individually bound Books making up thevarious components of the overall manual, ratherthan to produce the Books in loose-leaf binders intowhich periodic revisions can be inserted. In theOTM concept, Books are revised and updated ascomplete units, rather than piece-by-piece, toovercome distribution uncertainties, and theuncertainty of knowing whether a given versioncontains all the latest revisions. To identify the mostrecent versions of any OTM Books, the reader isadvised to contact MTO or the publisher, as notedimmediately following the Foreword.

1.4 Metrication

All sign dimensions on the sign patterns are shownin metric dimensions, in millimetres. (This isconsistent with most other engineering practice,where dimensions are typically given in metres andmillimetres. However, note that the first editions ofBooks 1, 1A, 5, 6, and 7 all provide dimensions incentimetres. The use of millimetres for signdimensions is new to the OTM, and isintroduced for the first time in Book 2. WhenBooks 1, 1A, 5, 6 and 7 are next updated, theirsign dimensions will be expressed in millimetres inconformance with the new sign dimensioningsystem used in Book 2.) This is satisfactory forsmaller signs using the standard metric sign blanks.A problem arises, however, when dealing withextruded panels.

Extruded aluminum panels and aluminum overlaypanels are manufactured in Imperial dimensions(feet, inches). What this means in practice is thatthe metric sign patterns have to be adapted to fitthe extruded sign panels in Imperial dimensions.This may typically be done using one of thefollowing approaches:

• The metric dimensions shown on the sign patterntemplate may be converted to their soft Imperialequivalent (e.g., 300 mm = 12 inches), eventhough 12 inches really equals 304.8 mm. SeeTable 2.10. The sign details are then developedentirely in Imperial units, and they will fit theextruded panels. This is quite a common practice.

• In the second approach, the dimensions of theextruded sign panels are converted from Imperialunits to metric units, using a hard metricconversion. Note however that the overall metricsign dimensions shown on the sign patterntemplate are rounded. For example, a 1200 mm x3000 mm sign shown on the template reallymeans a four-foot by ten-foot sign. Thesedimensions need to be converted to true (hard)metric, which means 1219 mm x 3048 mm. Thesign details are then developed entirely in metricunits to fit the extruded panels. The metricdimensions of the various sign elements (text,symbols, arrows) are used as shown on the signpattern template. They are then positioned on theextruded panels (Imperial units), according to theguidelines and rules for sign design and spacingof and between elements. Because the extrudedpanels are higher and wider than their soft metricequivalent, this means that spacings of andbetween elements are slightly larger than if theextruded sign panels were manufactured in thetrue metric size depicted on the sign patterntemplate.

More detail is provided in Section 2.15 (SignDesign Process). Section 2.14 (Rules for SignDesign) contains Table 2.10 (Imperial to MetricConversion Chart) for letter heights.



1.5 Bilingual and FrenchLanguage Sign Patterns

Bilingual (both English and French) and Frenchlanguage only sign designs are not shown in theOTM Policy Books, such as Books 5, 6, and 7.However, those bilingual and French language onlyversions of the signs, which have already beendeveloped by the Ministry of Transportation Ontario(MTO), are included in the Master Sign Library. Asnoted earlier, any bilingual or French language onlysign patterns will be shown in the sign number bythe suffix ‘B’ or ‘F’ respectively.

Occasions may arise where new bilingual or Frenchlanguage only versions of signs are required. TheFrench language text of any sign that is to beinstalled on a Provincial Highway located within anarea or areas designated by the French LanguageServices Act must be approved by MTO’s FrenchLanguage Services Office. Private sector companiesthat supply and/or install signs to the Ministry ofTransportation should request official translationsthrough their MTO Contract Administrator if theyare not already provided within the contract.

2. Guidelines for Sign Design

This section outlines guidelines for traffic signdesign (sometimes called sign detail). It includesboth sign design principles (Sections 2.1 to 2.13),and the application of those principles, including aset of sign design rules (Section 2.14), and therecommended sign design process (Section 2.15)for the creation of actual sign designs. The signdesign principles included in Book 2 are drawnfrom Book 1b (Sign Design Principles); they havebeen updated to include new information. They areincluded here to make Book 2 a manual that isessentially complete and self-contained.

A consistently applied set of sign design principlesis necessary to facilitate driver understanding of,and response to, sign messages. For the signdesign principles to be effective, they must bebased on measured visual and mental abilities ofroad users.

The outline of sign design principles in the OTM isintended to assist OTM users in understanding signdesign principles and related driver requirements.This knowledge will enable OTM users to:

• understand the design of existing signs in theOTM;

• design new local directional guide signs andother information signs;

• use the appropriate size of sign for a givenapplication;

• use the appropriate sheeting material and/or levelof illumination for a given application;

• mount each sign in an appropriate location;



• institute operational programs to ensure theongoing effectiveness of signage.

In outlining general sign design principles, thissection reflects traffic sign design principles that areconsidered to be good practice, applied currently byOntario road authorities.

2.1 Standardization of Design

High travel speeds and increasingly complex drivingenvironments require that signs be readily detectedand understood at a glance. Uniformity andsimplicity in design, position and application arecrucial for speedy detection and recognition. It istherefore important that sign design principles beconsistently applied, and that signs installed on allroads conform to the designs and standardsrepresented in the Ontario Traffic Manual.

Uniformity in design includes sign shape, colour,dimensions, symbols, wording, lettering, borders,and reflectorization or illumination. Many of the signdesigns in the Ontario Traffic Manual have beenapproved by the Traffic Operations andManagement Standing Committee (TOMSC) of theTransportation Association of Canada (TAC) after athorough review of various designs used in Canada,supplemented by test studies. Other signs havebeen approved by the Ministry of TransportationOntario (MTO) or by other Ontario road authorities.

Sign patterns for standard OTM signs are providedin the Book 2 Master Sign Library (MSL). All signshapes and colours are to be used as indicated inthe MSL. In addition, all symbols are to be the sameas those shown in Book 2, and wording onstandard signs containing text is to be as indicated.

Uniformity of application is also an importantelement of standardization. Similar conditionsshould be signed in the same manner, regardless ofactual location. It is recognized, however, that urban

conditions differ from rural conditions with respectto speed, frequency of intersections, trafficcongestion, parking and competing lights anddisplays. Where such differences in the driverenvironment impact the sign message, signapplication must take these differences intoaccount. Where practical, the OTM presentsseparate guidelines for rural and urban areas.

2.2 Approaches to Sign Design

Most regulatory, warning, and temporary conditionssigns (OTM Books 5, 6, and 7 respectively) havealready been designed as standard signs, and areshown as such on the sign pattern templates in theMaster Sign Library. The cut images shown onthese sign pattern templates for standard signs canbe used as shown, as described in Section 5(Master Sign Library). They do not need, nor arethey intended, to be redesigned. If operating speed,roadway width, or environmental considerationsmean that in certain situations a given sign doesnot provide drivers enough time to see and react tothe sign, the sign may be enhanced in one or moreways, such as larger sign size, sign repetition, orincreased reflectivity.

Other signs, primarily directional and informationsigns, have a sign pattern template but need to bedesigned to a greater or lesser degree. These signsare “customized standard signs.” That is, they arebuilt to a standard sign pattern template (includedin the MSL for illustrative purposes, without cutimages), but they need to be customized accordingto the local information message they convey, suchas destination or street name, and to the amountand type of information on the sign. In practicalterms, a higher (more generous) layout standard isoften used for overhead signs than for ground-mounted signs. This is reflected in the principles forsign design, in Section 2.8 (Sign Design Elementsand Arrangement), and in Section 2.14 (SignDesign Rules).



Other signs are “non-standard signs,” that is, thereis no sign pattern template, and the size andmessage are designed for a specific purpose.Although the same sign design principles and rulesapply to all signs (shape and colour codingaccording to type of sign, and sign design andlayout rules), the sign designer will need to applythose principles primarily for customized standardsigns and non-standard signs.

Section 5.1 describes the Master Sign Library,including the Sign Parts Library.

2.3 Driver Requirements

Sign design must take into account driverlimitations in detecting signs in the roadwayenvironment, processing the sign information, andselecting an appropriate response. Driver limitationsdetermine requirements for letter size, the selectionof font, contrast, retroreflectivity, spacing of signelements and borders, message layout, and readingtime, as well as longitudinal sign spacing andplacement in the field. The more a sign meetsdriver needs, the more likely a driver will detect it,the more likely he or she will be able to read andunderstand the message, and the more likely he orshe is to select the response desired by the trafficpractitioner.

Traditional sign design does not explicitly considerthese driver needs. In particular, no allowance ismade for the fact that longer messages requiremore time to read and therefore greater legibilitydistance. Nor is sufficient distinction made, in termsof sign placement, between signs requiring thedriver to make one of several choices and thencomplete a manoeuvre, as compared to signs thatare “information only.” Instead, a particular distanceis assumed, depending mainly on speed, and letterheight is determined through an assumed driverability of some number of metres legibility permillimetre of letter height. In the past this assumed

driver ability has been 0.6 metres legibility permillimetre of letter height (50 feet legibility per inchletter height), which does not encompass themajority of drivers, and assumes almost double theactual legibility distance of drivers with 20/40vision, licensable under MTO regulations.

Several criteria must be met for a sign to beeffective. Initially, it must command attention or beeasily detected by the person who needs theinformation (i.e., it must have good conspicuity). Itmust be legible at the appropriate distance (in timeto read the whole message and take the necessaryaction). At busy urban locations, signs, trafficsignals and markings can easily be hidden by largevehicles and seen only briefly. Therefore signsshould be readable quickly, as drivers often haveonly a second or two to interpret and respond tothe message. The message must obviously beunderstandable, otherwise the user will not knowwhether or how to respond to it. If the meaning ofthe message (e.g., a new symbol) is notimmediately understood, driver error or delay caneasily result. If a new symbol is introduced, aneducational text tab may be used temporarily to aidunderstanding.

Other, perhaps less obvious, criteria are that theinformation on the sign should be easily rejected ifit is irrelevant for the driver, and that the action tobe taken in response to the message should beimmediately obvious. Drivers often are in situationswhere there is a great deal of information from theroadway environment (not only signs). It may not bepossible to attend to and process all of thisinformation fully. The driver must be able to glanceat the sign and determine rapidly whether theinformation is relevant and should be processed,retained and acted upon. As all signs are possiblesources of relevant information, the driver must firsttake in and process the information at a superficiallevel before it can be decided whether it is relevant.This takes time and mental effort, which the drivermay not have under conditions of input overload



and stress. The appropriate action should notrequire a significant amount of thinking anddecision time, and should not violate driverexpectation, especially if the action involves amanoeuvre which must be taken quickly (e.g.,change lanes to exit or to avoid exiting ahead).

Finally, signs are most likely to be obeyed whenthey appear to be reasonable to the driver, andwhen they augment the roadway message ratherthan contradict it. For example, the use of speedsigns to lower speed, in the absence of changes inthe roadway, is likely to be ineffective.

In summary, the effectiveness of highway signsdepends on several factors:

• Conspicuity – does the sign attract attentiongiven the background in which it is placed;

• Legibility – at what distance can drivers read thesign;

• Information load – do drivers have sufficienttime to read the entire message;

• Comprehension – do drivers understand themeaning of the message, and any symbols orabbreviations used;

• Driver response – do drivers make the desiredaction as a result of reading the sign.

2.4 Shape and Colour Codes

Signs that are similar in function are typicallydesigned to be the same shape and to use thesame colour combinations for legends,backgrounds and borders. Shape and colour codesserve to organize pieces of information into largerunits and establish message redundancy. Driverscan recognize sign colours and shapes at fargreater distances than they can distinguish symbols

or read sign text. Colours can be identified first andtherefore colour coding is the most effective way tohelp drivers locate particular signs (e.g., guidesigns) quickly. The shape and colour codes alert thedriver to the general function of the sign. Theysimplify the driving task by enabling the road userto judge in advance the nature of the expectedresponse and to prepare accordingly. For example,drivers can recognize the shape and colour of theSTOP sign before they can actually read the signtext. In fact, the STOP sign is one case where theshape and colour convention has made the sign sofamiliar to drivers that actually reading the text hasbecome unnecessary.

All signs in the OTM have been allocated to classesand sub-classes, according to the specific functionof the sign. For example, Class R representsregulatory signs, which regulate the flow of trafficby instructing drivers on what they must or shoulddo. Sub-class Ra, within Class R, refers to right-of-way control signs, which regulate the right-of-way ofvehicles and other users at locations where theirmovements may otherwise be in conflict.

Unique sign shape and colour codes have beenassigned to each sign class, with further shape andcolour distinctions provided for some sub-classes,and in some cases even within the sub-class. Forexample, Class R regulatory signs are generallyrectangular in shape and have white backgroundswith black legends. Sub-class Ra signs includesome signs with shape and colour codes thatfollow the general rule for Class R, but also somespecial signs, such as the STOP sign and YIELDsign, which have their own unique shape andcolour codes. Shape and colour codes for signclasses and sub-classes are illustrated in Table 2.1.

Clearly, shape and colour codes are a powerfulelement of sign design. Therefore, all signs mustfollow the shape and colour codes indicated in theOTM. Precise sign shapes are specified in the OTMBook 2 Master Sign Library. Sign colours must be inaccordance with the ASTM (American Society for



Table 2.1 – Shape and Colour Codes for Signs



Testing and Materials) Specification D 4956-01a(or its subsequent revisions), typically used bymanufacturers of signs and sign sheeting materials.A similar specification available in Canada is theCGSB (Canadian General Standards Board)Specification 62-GP-11. Sign colours specified in theOTM are based on ASTM Specification D 4956-01a.

To ensure immediate recognition of signs, it isimportant that the correct shades of the colours areused. Also, signs required at night must retain thesame colour by night as by day through use ofretroreflective sheeting or internal or externalillumination. See Section 2.9 (Reflectorization andIllumination). Signs discolour with age, due toultraviolet radiation and deterioration ofretroreflective sheeting. To alleviate this problem,regular programs for sign maintenance, inspectionand inventory are recommended. This will becovered in the upcoming OTM Book 4 (SignMaintenance).

2.5 Text Legends

Many of the signs in the OTM are text-based, as it isdifficult to clearly convey certain complex messagesusing symbols. In determining the text to be usedon a sign, font, letter height and the use of uppercase versus mixed case letters must be considered.

2.5.1 Fonts

A font is a selection of type of one face, or style,including letters and numbers of unified design andgiven size. The font type determines theappearance of the letters, as well as the ratio ofletter height to letter width, stroke width of theletter relative to letter height, the kerning or spacebetween letters and the spacing between words.

At the time of publication, the sign fonts used in theOTM are primarily the FHWA 2001 CanadianEdition, Series C, D, E, and E(m) or E (modified)fonts prescribed by the FHWA and used by theMTO. See Figure 2.1. The Canadian edition includesFrench characters.

The FHWA Series C, D, and E fonts were originallydeveloped as upper-case fonts only, while theSeries E(m) font was developed for use of bothupper- and lower-case characters. The letter widthto letter height ratio, the stroke width to letterheight ratio and the spacing between letters allgenerally increase as the font series progressesfrom C to D to E to E(m). For letters of equal height,a number of studies have shown that Series E andE(m) letters are significantly more legible thanSeries C or Series D letters of the same height.Series C and D fonts are typically used forregulatory signs, which are quite familiar to driversand are often easily recognized by their shape andcolour codes, while Series E and E(m) are used fordirectional guide signs, which have uniquemessages and rely for effectiveness on whether ornot they can be easily read.

Figure 2.1 – Example of FHWA Fonts



Less frequently used fonts for sign text in the OTMare: Series B and F, Helvetica Medium, HelveticaBold Condensed, Century Bold, and CenturyCondensed Bold.

The Clearview font was recently developedspecifically for traffic signs. Because of theincreased openness of Clearview characters, ittakes up 12% less sign space than words in SeriesE(m), while providing the same amount of legibility.When Clearview font spacing is increased to 112%,the letters occupy the same sign space as theSeries E(m) font. In this case, legibility is improvedby 16% for drivers aged 65 and older. Some studieshave suggested that daytime legibility relative toSeries E(m) is not changed by using Clearview.Based on the cited advantages indicated by somestudies, Clearview is currently being reviewed byseveral road authorities for its potential application.At this time Clearview is not part of the MTOstandard and therefore is not used in the MasterSign Library.

2.5.2 Letter Height

In order for a sign to be effective, it must be legibleat a distance which allows a driver to read it andcarry out any required actions before reaching thesign. When the message is lengthy (e.g., severaldestination names, or complex constructioninformation), drivers will need more time to read theentire message than for a sign with a single symbolor a word or two. In addition, if the driver mustcarry out some action, such as a lane change or astop before reaching the sign, then it must belegible at a distance that allows the driver both toread it and respond before reaching the sign. Oneof the key factors in ensuring sign legibility at therequired distance is the letter height. For details oncalculating letter height which is adequate for themajority of drivers, see Section 2.7 (CalculatingLetter Height and Symbol Size).

2.5.3 Upper and Mixed Case

While upper case letters are more legible forunfamiliar words, mixed case (upper and lowercase) has better legibility for familiar words. This isbecause words in mixed case form a distinctshape. If the driver knows the word he or she islooking for, it will be possible to recognize theshape of the envelope created by the uniquepattern of dots, letter ascenders and descenders,well before the letters can be individually resolved.Mixed case is most appropriate for guide signsbecause drivers generally have a particulardestination in mind and are looking for that word.Mixed case will not be as legible as all upper-casewhere drivers do not know what message toexpect, for example, advance signs for constructionzones.

Signs in most of the sign classes have traditionallyused upper case letters. For most signs, it isdesirable from the standpoint of driver familiarityand uniformity to maintain consistency withexisting sign standards. However, in the case ofdirectional guide signs, tourist signs and streetname signs, mixed case should be used to supportimproved word recognition. Cardinal directions oninformation signs (e.g., north, west) may be shownin upper case when used in a mixed case context,to draw attention to the word and to make theword function almost as a symbol. Based on long-standing practice, MTO uses mixed case for placenames/destinations on guide signs, except forthose on non-freeway ground-mounted signs,where all upper case is used.

2.5.4 Horizontal Reduction

When a sign message does not fit onto a signblank, there may be a tendency to reduce thewidth of the letters until the message fits.Squeezing text alters the typeface, thereforereducing legibility, and should be avoided. On those



rare occasions when horizontal reduction cannotbe avoided, the length of a word should bereduced by no more than 10% to make amessage fit onto a given blank size. If themessage still will not fit on the sign blank, the nextlower font series may need to be used (i.e., movefrom Series D to Series C).

2.6 Symbolic Legends

Symbols can convey in a single image the samemessage that may require several words of text.Therefore the symbol size is generally considerablylarger than individual letters, making the signlegible at greater distances (on average, doublethe distance) as compared to the equivalent wordmessage. Due to the significant legibility benefitsof symbol signs, their use is encouraged whereverpractical.

In order to be effective, though, the meaning ofthe symbol must be understood by a highpercentage of the driver population. It is thereforerecommended that, when a new symbol isdesigned, it is tested with representative driversand not simply shown to other traffic practitioners.Methods to do this are described in Section 2.13(Process for Assessing and Revising SignDesigns). Testing, which is followed by anyredesign necessary to eliminate driver confusion,should alleviate difficulties in comprehension.Where symbols are understood by fewer than85% of drivers, educational tabs may be used toassist comprehension. Good initial design willavoid signs which are ineffective and/or whichrequire expensive educational campaigns toinform drivers of their meaning.

For details on calculating symbol size, see Section2.7 (Calculating Letter Height and Symbol Size).

2.6.1 Arrow Type and Size

Arrows are used extensively as symbols on trafficsigns for the following basic purposes:

• To indicate the direction and path of travel, withthe arrowhead indicating direction and the shaftindicating the path of travel;

• To indicate the direction and path of travel, butwith the arrowhead pointing down rather than up(e.g., exit only ramp signs);

• To indicate the distance ahead on the road towhich a sign condition refers, with the arrowheadindicating the direction of the road ahead;

• To indicate dimensions on or around the road(e.g., vertical or lateral clearance), with thearrowhead indicating the direction of theassociated dimension.

• Various types of arrows and their meanings areillustrated and summarized in Table 2.2.

When an arrow with a full shaft is used, care mustbe taken to avoid having too short a shaft, relativeto the dimensions of the arrowhead. A shaft at leastdouble the length of the arrowhead is preferred.

Patterns for all arrows are available in the Sign PartsLibrary in the MSL.

2.6.2 Interdictory and Permissive Symbols

The convention of using interdictory and permissivesymbols superimposed on other symbols is appliedthroughout the OTM. The interdictory symbolconsists of a red annular band or circle with adiagonal red stroke. This symbol signifies that theaction represented by the symbol inside the circleand covered by the diagonal red stroke isprohibited. The diagonal red stroke runs from the



Table 2.2 – Shape and Function of Arrows



top left of the circle to the bottom right, or from thetop right to the bottom left, at an angle of 45degrees to the horizontal. If the diagonal stroke atthis angle obliterates the symbol representing theprohibited action, an angle as close as practicableto 45 degrees should be used.

The permissive symbol consists of a green annularband or circle surrounding another symbol. Thissymbol signifies that the action represented by thesymbol inside the circle is permitted. By inference,an action contrary to that represented by thesymbol inside the circle may be prohibited.

For some applications, such as turn control signs, itis strongly recommended that the interdictorysymbol be used rather than the permissive symbol.The interdictory symbol is preferred for bothcomprehension and enforceability, since it moredirectly indicates the action prohibited. With thepermissive symbol, the driver must go through anadditional step to interpret that actions contrary tothe permitted one(s) are prohibited. For example, itis not necessarily clear to all drivers that apermissive turn control sign indicating that rightturns and straight through movements arepermitted means that left turns are not allowed.Also, permissive regulatory signs for moving trafficmay be more difficult to enforce than interdictoryregulatory signs.

Permissive signs, however, do have a practical rolein the OTM. In some cases it is awkward to expressa message using an interdictory sign where apermissive sign is straightforward, for example,signs indicating permitted parking durations. Thepermissive sign also is used to indicate that anupstream prohibition indicated by an interdictorysign, such as a no passing restriction, is no longerin effect. There are still other applications, such assigning for heavy truck routes, in which thepermissive and prohibitive systems can worktogether. In this case, the permissive signs aretypically used to indicate a continuous route

preferred for heavy truck use, supplemented byprohibitive signs installed where there is ademonstrated problem with trucks using a non-designated route

2.6.3 Logo Design

With the new tourist signing system, numerouslogos are being used on traffic signs. In some casesthese logos were developed for letterheads and areintended to be viewed at arm’s length. Such logosare not easily recognized on highway signs wherethey are seen at 100 m or more for a second ortwo. For easy recognition, logos should be:

• Simple in design – small details will not beresolvable at distances at which highway signsare read;

• Simple in colour – use of colour should berestricted so that the different coloured areas canbe resolved at a distance – 3 or fewer colours arepreferable;

• Evaluated at the distance at which drivers willhave to read them – a design which is attractivewhen viewed at arm’s length, may be clutteredand difficult to resolve at long distances whenseen briefly.

2.7 Calculating Letter Heightand Symbol Size

A number of factors must be considered to ensurethat signs are legible at an appropriate distance.The following steps should be used to determinethe minimum letter height on a text sign, or thesymbol size on a symbol sign, to accommodate themajority of the driving population:



(1) Reading Time – Calculate the time requiredto read a sign with a given message.

(2) Decision Time – Determine the time requiredto make a decision and initiate a manoeuvre,(if one is required).

(3) Manoeuvre Time – Determine the time tocomplete any required manoeuvre beforereaching the sign.

(4) Required Legibility Distance – Determinethe distance at which the sign must belegible, based on the travel speed (usually thespeed limit) and the sum of the timesobtained in Steps 1, 2 and 3 above.

(5) Minimum Letter Height – Calculateminimum acceptable letter height using setratios for legibility distance-to-letter-height,specific to the font used.

(6) Symbol Legibility – Calculate symbol sizebased on legibility distance and the width ofthe critical detail in the symbol.

This process, while based on reasonable driverrequirements, tends to be conservative, since itdoes not fully account for redundant information.For example, the presence of advance guide signswill likely reduce the time required to recognize andread a sign at a freeway exit.

As is noted in Section 2.13, this process was notused to arrive at many current sign designs.Because most regulatory signs and warning signscontain few words or symbols, and are for the mostpart very familiar to drivers, and because relativelyfew signs require that a manoeuvre be completedbefore the sign is reached, it is likely that futureanalysis will show that most current signs meetdriver needs. The signs which are of real concern interms of letter height are those with long messages,with information that is new to the driver, or which

must be read in their entirety. These signs includesome guide signs, tourism signs, advanceconstruction notification signs and left turnrestriction signs.

Tourism signs have been developed using a processwhich considered driver requirements, and thestandards developed and described in Book 9(Tourism and Commercial Signs, not yet developed)will be based on this process. However, guide signsand information signs are continually beingdeveloped to suit the requirements of specificlocations. The method outlined in this sectionshould be used to determine appropriate letterheights for these signs. The reading times given donot apply to variable message signs. These arediscussed in Book 10 (Dynamic Message Signs).

2.7.1 Reading Time

Reading time should be considered to be on theorder of 1/2 second per word or number (with 3seconds as a minimum for total reading time, if nodecision or manoeuvre is required), and 1 secondper symbol. If some of the sign information isredundant, then reading time should becalculated for the critical words only.

For example, when drivers read destination signs,they do not need to read every word of eachdestination. If they are looking for Avenue Road,they do not need to read both “Avenue” and“Road”, since the road is assumed. Similarly, if theyare looking for Avenue Road, they only need readthe “Yonge” of “Yonge Street” to realize that this isnot the destination they are looking for and theycan go quickly to the next line in the sign.



Furthermore, if drivers are reading a list ofdestination names, they only need to read thearrow direction for the place name they aresearching for.

Reading Time [secs]= 1 * (no. of symbols)+ 0.5 * (no. of words and numbers)

Notes:

(1) The time of 1/2 second per major word is anapproximation. If the sign is confusing todrivers, or does not contain the informationthat the driver is expecting or looking for, thenreading time will be longer. In fact, a signwith more information can be read morequickly than one with less information, if theformer sign contains the information that thedriver is looking for and the latter sign doesnot. Where there is any potential forconfusion, signs should be tested to ensurethe sign design is optimal. Differences inreading time between a good and a poor signcan be several seconds. And it is not onlylegibility that is affected. In general, thelonger it takes to read a highway sign, themore errors there will be in responding to it.

(2) Minimum reading time should be consideredto be 3 seconds, where no decision ormanoeuvre is required. Signs legible for lessthan this time are too easily missed simplybecause a driver may have to glanceelsewhere, or the sign may be blocked fromview by other traffic in the short period oftime available. Where a decision ormanoeuvre is required, the minimum readingtime plus decision time should be consideredto be 3 seconds.

(3) If there are more than 4 words on a sign, adriver must glance at it more than once, andlook back to the road and at the sign again.This glance away and back takes

approximately 3/4 second. For everyadditional 4 words and numbers, or every 2symbols, an additional 3/4 second should beadded to the reading time.

(4) When the sign is very close, it is seen on anangle, and becomes difficult to read. It isassumed that the sign is not read for the last1/2 second. This is called the “out-of-viewtime.” Therefore, 1/2 second is added to therequired reading time. The only exception tothis is signs requiring a manoeuvre before thesign is reached, as they would not be read atthis close distance.

2.7.2 Decision Time

Once a driver has detected and then read the sign,he or she is in an alerted state, ready to make adecision and initiate a manoeuvre. The timerequired to do this is the decision time. Many signsare for information only and do not require anyresponse. Decision time can be considered to bezero in these cases.

Most signs that do require a decision, require astraightforward one, e.g., stop, or reduce speed. Forthese signs, given that drivers are in an alertedstate and the choice about what to do is verylimited, decision time can be considered to be 1second. If the driver is presented with severalchoices about what to do, or if the decision iscomplex because of the roadway layout, thenlonger decision times will occur. In such situations,up to 2.5 seconds may be required.

2.7.3 Manoeuvre Time

The requirement to complete a manoeuvre, and thetype of manoeuvre required can add significantly tothe total time required for a driver to read andrespond to a traffic sign, and consequently to the



distance at which a sign must be legible. Forexample, where there is no advance sign, and aroad name sign is placed at an intersection,considerable legibility distance is required. Thedistance must be sufficient to allow drivers to readthe name, and in response, to change lanes, and toslow down prior to turning. Therefore it must berecognized at a greater distance than an advanceroad name sign, which simply alerts the driver toan intersection ahead, but does not require a driverto complete any actions before reaching the sign.

There are two main types of manoeuvres: lanechanges and speed reductions, including thoseresulting in a total stop.

For lane changes, manoeuvre time is a sum of thetime required to search for a gap in traffic and thetime to actually perform the lane change. Gapsearch time increases as traffic volume increases,since it is more difficult to find suitable gaps intraffic. Lane change manoeuvre time is calculatedfor passenger vehicles using Table 2.3.

For speed reductions, a constant deceleration rateof 8.8 km/(h*sec) is assumed, described as areasonably comfortable braking rate, in theTransportation and Traffic Engineering Handbook.Therefore, the manoeuvre time can be calculatedas follows:

Manoeuvre Time (for speed reduction) [secs]

If the speed reduction results in a stop, as requiredfor a STOP sign, the final speed is zero, and theabove equation is simplified to the following:

Manoeuvre Time (for stopping) [secs]

2.7.4 Required Legibility Distance

The required legibility distance is calculated asfollows:

If neither a manoeuvre nor a decision is required,

Total Time Required [secs]= Reading Time + Out-of-View Time= Reading Time + 0.5 secs (min. 3.5 seconds)

If a manoeuvre is required,

Total Time Required [secs]= Reading Time + Decision Time + Manoeuvre Time

Legibility Distance [metres]= Total Time Required [secs]

* Travel Speed [km/h] * 0.28 [(m/sec)/(km/h)]

Traffic Volume Gap Search Time Lane Change Time Total Manoeuvre Time[secs] [secs] [secs]

Low 3.5 4.5 8.0

High 5.3 4.5 9.8

Table 2.3 – Lane Change Manoeuvre Time



2.7.5 Minimum Letter Height

Table 2.4 shows the legibility-distance-to-letter-height ratio according to font. Note that the ratio ishigher for Series E(m) font than for the narrowerSeries C and D fonts that have poorer legibility. Thehigher ratio for Series E(m) font means that, for agiven letter height, this font is legible from a greaterdistance than are Series C and D fonts. Clearviewhas the same legibility-distance-to-letter-height ratioas the Series E(m) font (but takes up 12% lesshorizontal space).

Minimum letter height is calculated as follows:

Minimum Letter Height [mm]

2.7.6 Symbol Legibility

The most legible symbols are those with boldstrokes and simple, distinctive shapes (e.g.,T-intersection, Y-intersection, Cross Road). The leastlegible symbols have small details that must beseen (e.g., Pavement Ends, No Trucks). The bestsymbol signs are legible at as much as 3 times thedistance of the least legible (approximately 300 mversus 100 m average legibility for typical warningand regulatory symbol signs and a sample of

young, middle-aged, and elderly drivers). Becausethe legibility of symbols depends on the complexityof the design, as well as on the smallest criticaldetail that must be resolved, it is difficult to predictwhat the legibility will be without testing. It shouldbe noted that there is an interaction betweenlegibility and comprehension. Symbols that arepoorly understood will be less legible than symbolswith similar designs, in terms of size of detail andcomplexity, that are better understood.

2.7.7 Example

Consider a destination sign with two names andtwo arrows, placed 30 m from the intersection on atwo-lane highway, where there is no advancesigning (see Figure 2.2). This is a situation that canoccur on secondary highways, but not on primaryhighways where advance signing is used. Thedriver potentially must slow from 80 to 40 km/h inorder to turn at the intersection. Therefore the drivermust be able to read at least two words and onearrow direction to make a decision. The driver mustthen begin to brake, and slow down to 40 km/hbefore reaching the intersection.

Reading Time = Tr

= (1 sec/symbol) * (1 symbol)+ (0.5 secs/word) * (2 words)= 2 secs

Decision Time = Td

= 1 sec

Reading Time + Decision Time= 3 seconds (= minimum 3 seconds)

Manoeuvre Time (for speed reduction) = Tm

Table 2.4Legibility-Distance-to-Letter-Height Ratios

Legibility-Distance-toFont Letter-Height Ratio [m/mm]

Series C 0.42Series D 0.42Series E 0.48Series E(m) 0.48Clearview 0.48



Total Time Required [secs] = Ttotal

= Tr + Td + Tm

= 2 + 1 + 4.5= 7.5 secs

Travel Speed [km/h] = Vo

(where Vi = initial speed and Vavg = average speed)

Required Legibility Distance [m] = Dlr

= Ttotal [secs] * Vo [km/h] * 0.28 [(m/sec)/(km/h)]

= 7.5 secs * 68 km/h * 0.28 [(m/sec)/(km/h)]

= 143 m

(where 0.28 is the conversion factor from km/hto m/sec)

Since the sign is 30 m from the turning point, thespeed reduction can continue for 30 m after thesign is passed. Therefore, required legibility distancecan be reduced by 30 m to 113 m.

Minimum Letter Height [mm]

The calculations for letter height are based onvalues intended to ensure that the majority ofdrivers will have ample time to read signs and carryout manoeuvres. Sign blanks come in standardsizes and the maximum letter heights possiblegiven the sign blank size may not allow thecalculated letter height. To allow some flexibility forpractical reasons, it is recommended that the actualletter height used be no smaller than 90% of thecalculated value.

2.8 Sign Design Elementsand Arrangement

Following on the development of some generalguidelines for the design of sign text and symbols,this section considers how these elements arearranged on the sign face. Aspects of design toconsider include the length of the message on asign, the distribution of the legend on the sign,interline spacing and border space.

Figure 2.2 – Example Sign



2.8.1 Message Length

For the purposes of reduced reading time andincreased legibility, it is important to minimize themessage length, provided that the messagedoes not become ambiguous. A sign with alonger message will have to be legible from furtherback, and will therefore need to have larger text anda larger overall size, than a sign with a shortermessage in the same environment and requiringthe same driver response.

Message length will determine letter height, andtherefore sign size. The method described inSection 2.7 (Calculating Letter Height and SymbolSize), which considers driver visual capabilities,reading time, decision time and manoeuvre time,should be used to calculate letter height.

2.8.2 Interline Spacing

Interline spacing is the vertical distance betweenlines of text. Sufficient interline spacing must existon sign text so that the lines of text are legible froma distance. The general guideline is to provide aspace of 0.5 to 1.0 times the maximum letterheight between each pair of lines. Section 2.14contains recommended rules for sign interlinespacing.

For signs using mixed case text, the impacts onlegibility and overall aesthetic effect caused byinteracting ascenders and descenders (e.g., thevertical stroke of the letter ‘b’ and the vertical strokeof the letter ‘p’) need to be taken into account. Ifascender/descender interference results withstandard interline spacing, the space between thelines should be slightly increased and the legendcentred vertically on the sign blank.

2.8.3 Border Space

Sign borders delineate the sign against itsbackground environment, help direct driverattention to the message and can differentiatemessages within groups of signs. Three kinds ofborders are used on signs in the OTM:

(1) Inner Border: a continuous narrow strip thesame colour as the legend, just inside theedge of the sign. This type of border improvesthe appearance of the sign. The width of theinner border should be approximately 1.5% to3% of the smallest outer dimension of thesign. For a 600 mm x 600 mm sign, thistranslates to about 10 to 15 mm.

(2) Outer Border: a continuous narrow frame thesame colour as the sign background, at thevery edge of the sign. The outer borderemphasizes the inner border by providingcontrasting colour on both sides of the innerborder. The outer border is used only on signswith light backgrounds and dark legends. Thewidth of the outer border should beapproximately 1.5% of the smallest outerdimension of the sign. For a 600 mm x600 mm sign, this translates to about10 mm.

(3) Background Space Around Legend: emptybackground space between the legend andthe inner border. This space is required sothat the legend is clearly distinguishable froma border of the same colour.

On regulatory, warning and temporaryconditions signs, the minimum clearancebetween the legend and inner border shouldbe approximately 4% to 10% of the smallestouter dimension of the sign. For a 600 mm x600 mm sign, this translates to about 25 to60 mm.



On directional guide signs and otherinformation signs, the minimum sideclearance between the legend and the insideof the border should be equal to the heightof the largest letter. The minimum verticalclearance between the legend and the top orbottom of the sign should be 0.67 to 1.0times the largest letter height.

Section 2.14 contains recommended rules for signdesign, including detailed rules for border size andcornering.

2.9 Reflectorization and Illumination

Signs that convey messages of warning, importantregulations or essential directional information thatare relevant during the hours of darkness need tobe legible and conspicuous at night, as well asduring the day. Since conspicuity depends to somedegree on colour code recognition, the colour ofthe sign must appear the same by night as by day.The engineering tools used for maintaining areasonable level of sign legibility and conspicuity atnight are reflectorization and illumination.

2.9.1 Retroreflective Sheeting

Most signs are assembled by applying thinadhesive sheeting materials in the background andlegend colours to a rigid sign blank. Some types ofsheeting contain tiny glass beads or prisms thatrefract the light so most of it is reflected straightback to the source, which is a vehicle withheadlights. Therefore, the light from the headlightsis very efficiently used, with a significant amount ofit reflected back towards the driver’s eyes. Materialhaving this property is known as retroreflectivesheeting.

There are different types of retroreflective sheeting,ranging from Type I (Engineering Grade) to Type IX.Types of retroreflective sheeting are discussed inmore detail in Section 3 (Sign Materials). In general,the higher the type number, the greater the amountof light reflected back to the driver’s eyes, thoughthis does not necessarily apply for Types VII, VIII andIX. Each type of retroreflective sheeting ischaracterized by a range of R-values. R is known asthe coefficient of retroreflectivity and indicates theproportion of light reflected back to the driver. Theunits for R are candelas per lux per square metre(cd/(lux-m2)). For a given type of retroreflectivesheeting, the R-values vary according to colour, withdarker colours having generally lower R-values.

R-values associated with each type of retroreflectivesheeting are detailed in the ASTM Specification D4956-01a (or its subsequent revisions), and this isthe standard used in the OTM. In Canada, the CGSBSpecification 62-GP-11 (or its subsequent revisions)also specifies retroreflective sheeting for somegrades of sheeting. Specifications for retroreflectivesheeting, including ASTM R-values for commonlyused types of sheeting, are further discussed inSection 3 (Sign Materials).

2.9.2 Illumination

As an alternative or supplement to retroreflectivesheeting, external or internal illumination of the signmay be used. As with retroreflective sheeting, allsign illumination must result in sign coloursappearing the same by night as by day. Illuminationmay be by one of the following means:

(1) A light behind a translucent sign face,illuminating the legend and/or background;



(2) An attached or independently mounted lightsource designed to direct essentially uniformillumination over the entire sign face;

(3) Luminous tubing shaped to the legend orsymbol.

Ordinary street or highway lighting does not meetthe requirements for sign illumination.

2.10 Contrast

Contrast refers to differences in colour or inbrightness which allow a target, such as a signmessage or symbol, to be seen against the signbackground. Contrast is dependent on a propertycalled reflectance, which represents the amount oflight reflected back from a sign, relative to theamount of light shining on the sign. Contrast isdefined in various ways. Contrast can be calculatedaccording to the following formula:

Contrast affects legibility. Where there is a low levelof contrast (e.g., orange letters on a light bluebackground) legibility will be poorer than withhigher contrast (e.g., black letters on a whitebackground). Table 2.5 shows acceptable andrecommended combinations for sign colours usedin the Ontario Traffic Manual, based on contrast.

During the day, contrast is determined by thedegree to which various colours reflect light. Atnight, light is provided by streetlights andheadlights. Even with these light sources there isinsufficient light reflected from a non-retroreflectivesign to allow it to be read. In order to raise the levelof light reflected back to the observer, retroreflectivesheeting is used. See Section 2.9 (Reflectorizationand Illumination). For a sign with retroreflectivesheeting, reflectance at night is measured by theR-values of the materials used for the sign legendand background.

2.10.1 Positive Contrast Signs

For positive contrast signs (e.g., white legends ongreen or blue or red backgrounds), brightnesscontrast at night has a major impact on legibility.Laboratory studies have shown that:

• Legibility falls off rapidly for contrast ratios belowabout 4:1;

• Best legibility is found for contrast ratios in theregion of 10:1 to 15:1;

• Beyond contrast ratios of 15:1, legibility verygradually decreases, but even at 100:1 it is stillgreater than at 4:1.

For this reason, sheeting combinations whoserelative R-values (see Table 3.2 in Section 3)produce contrast ratios below a value of 4:1 orabove a value of 100:1 are not recommended. Atthe upper end, laboratory studies have shown thatnight legibility is significantly reduced for Type VIIlegends on a Type I (Engineering Grade)background. Thus this combination is notrecommended.

Some signs, such as STOP signs, are fabricated byscreening coloured transparent ink onto whitesheeting. When new, ink tends to have a lowerR-value for a given colour than its equivalent level of



sheeting, resulting in higher contrast ratios with thewhite sheeting. However, the ink fades more quicklythan sheeting, and with time, contrast ratios fallbelow those for the same types of signs surfacedentirely with sheeting. For best results, it isrecommended that components of screened signs(e.g., sheeting, ink, clear coating) be provided fromthe same manufacturer to ensure compatibility ofthe components.

2.10.2 Negative Contrast Signs

For negative contrast signs with black legends onwhite or orange backgrounds, the retroreflectanceof the black sheeting is zero, and a contrast ratiocannot be calculated. (For other negative contrastsigns, such as blue legends on white background, acontrast ratio can be calculated.) For such signs,nighttime legibility depends on sign luminance.

Table 2.5 – Acceptable Sign Colour Combinations Based on Brightness Contrast



Studies show that with Series C letters, there is littleimpact of sheeting on legibility – legibility is asgood with Type I as with Type IV sheeting. WithSeries D letters, Type III and IV sheeting increaselegibility over that of Type I and II by about one-third. Signs with black backgrounds shouldgenerally be avoided, given the lack of reflectanceof the majority of sign area and the resulting lowillumination of the sign.

2.11 Selecting the Sign Size

Books 5, 6, 7, 8 and 9 of the OTM show signdesigns and minimum sizes of signs, typically asrelated to type and speed of roads. Most signscurrently in use are considered to meet the needsof the majority of drivers, based on experience inOntario and elsewhere. However, these signs havenot all been systematically analyzed in accordancewith the sign design principles described herein.This is proposed to be done over a period of time,through the process outlined in Section 2.13. Overa period of time, revisions and refinements to theOTM will be made on a continuing basis. At anygiven time, the OTM Books and the minimum signsizes shown therein represent best guidance andpractice based on current knowledge at the time.

In some situations, it may be desirable to increasethe sign size over those shown in the OTM. Muchof the information discussed in the above sections(especially Section 2.7), including font, letter size,symbol size and sign layout with appropriatespacing and borders, can be used to determinewhether increased sign size should be used. Thestandard sign size can then be adjusted to fit thenext larger standard sign blank size available (SeeTable 5.1, Standard Sign Blanks, in Section 5). Formost large guide signs, both overhead and ground-mounted, a height dimension is specified and thewidth dimension is dependent on the messagelength. When the size of this type of sign is

increased beyond 3.6 m (12 feet), the width of thesign is increased in even 600 mm (2 foot)increments, with the exception of the 4.57 m (15foot) sign width.

Some of these situations where larger sign size maybe desirable, include the following:

• If there are factors that impact the amount oftime a driver can devote to reading the sign, suchas a complex and distracting backgroundenvironment, heavy traffic volumes and a highdensity of intersections and driveways requiringcomplex choices, consideration should be givento moving up to the next larger blank size, toincrease the distance at which the sign is legible.

• Similarly, in areas where high collision rates orhigh conflict rates are attributable to driversfailing to notice the sign, consideration should begiven to increasing the sign size.

• If there is a known challenged driver populationin a given area, such as in the vicinity of a seniorcitizens’ centre, consideration should be given tomoving up to the next larger sign blank size.

If the required sign size is prohibitively large and ifattempts to redesign the sign have not succeededin the short term, consideration should be given tousing a higher intensity sheeting to improvenighttime legibility. For example, increasing theintensity of sheeting from Type II to Type IX forboth legend and background has the equivalentimpact of increasing night legibility distance by 15to 30 m, or increasing the letter height by 25 to50 mm for nighttime conditions only.

It may not be economically feasible to install allnew signs and to replace all damaged and agedsigns with the sizes required to accommodate 85%of the driving population. In this case, priorityshould be given to signs that are higher on the signhierarchy (see Book 1).



In some situations, however, there are constraintson maximum sign size. In city centres, locations forinstalling guide signs are limited due to competitionfrom other signs, limited boulevard space, polestructural limitations, and the like. The surface areaof overhead signs mounted on freeway trusssupports is limited to 42 square metres (450 squarefeet), with a maximum height of 2.75 m (9 feet),due to wind loading forces. Under somecircumstances, available horizontal space is thecontrolling factor. A sign mounted over a roadwaylane may have to be limited in horizontal dimensionto the width of the lane, so that another sign maybe placed over an adjacent lane. For ground-mounted signs, specific sign structures (i.e., verticalsupports and cross-arms) are designed toaccommodate specific sizes of signs. For largersigns, a stronger structure must be used.

2.12 Bilingual Sign Design

Signs with text in both English and French may beinstalled in designated areas, conforming withmunicipal and provincial policies (see Book 1,Section 8 for information on bilingual signingpolicy). Bilingual messages can be presented eitheron the same sign or on separate signs. If bothlanguages are shown on one sign, one of twooptions must be used:

• English text on the left side and French text onthe right side; or

• English text on the upper portion of the sign withFrench text below.

If a pair of signs is used instead, the English textmust be presented first and its French textequivalent must be located beyond it. The signsshould be placed far enough apart so that both arelegible, but close enough so that their individual

messages can be recognized as being equivalent.For longer texts, the two-sign approach is preferred,to avoid overloading the driver with what mayappear as a lengthy message.

Bilingual signs must conform to established signdesign principles for application, location, position,colour, shape and size. They must employ the samesymbols, arrows and borders, and where possiblemust maintain the same fonts and equivalent letterheights as their corresponding English-onlyversions. Sign patterns for bilingual signs areshown in the Master Sign Library. See also Sections2.14 (Sign Design Rules) and 2.15 (Sign DesignProcess).

2.13 Process for Assessingand Revising Sign Designs

A cursory analysis would suggest that most signscurrently in use probably do meet the needs of themajority of drivers, despite the fact that they weredesigned in the absence of explicit knowledge ofdriver needs. However, a systematic analysis isrequired because there are signs which appear tobe inadequate. Given the aging of the driverpopulation and the increasing complexity of theroad network, it is important that such signs beconsidered for redesign. In addition, such ananalysis is needed to ensure that sign sizesdesignated for various road types and speed zonesare appropriate.

Due to the time required to complete an analysis ofthis depth, it is not possible to incorporate theanalysis results for the sign designs of the first fewOTM Books to be released. A process has beenstarted, however, which will eventually lead to theupdate of sign designs as required throughout theentire Ontario Traffic Manual (see Book 1, Sections2.5 and 5.12). The process involves the followingsteps:



(1) On an interim basis, for each edition of theOntario Traffic Manual, use the currentversions of the regulatory, warning, temporaryconditions, and guide signs included in theOTM Books, specifying different minimumsizes of signs for different speed ranges,according to rule of thumb and commonlyused sign blank sizes. Increases above theseminimum sizes may become desirable whenother factors and sign design principles aretaken into account.

(2) On a longer-term basis, adopt a procedure forsign review and revision, involving the Ontariotraffic engineering community, through theOntario Traffic Manual Committee (OTMC)and its subcommittees. This procedure isenvisaged as follows:

(a) Existing Signs – Identify those signswhich appear most problematic, andsubject them to systematic analysis ofdriver requirements, to determine theappropriate letter height. Develop andtest for comprehension alternative signdesigns for any signs that are found tobe deficient, or that appear to requiresignificant increases in sign size.Discuss alternatives at the OTMC andapprove the approach preferred by theOTMC, which would be incorporated inthe next edition of the relevant Book ofthe OTM. Over time, all existing signsshould be reviewed in this manner.

(b) New Signs – Any new sign designs (allcategories) should be developed on thebasis of current knowledge of driverneeds, as discussed in Section 2.3. Ifthe resulting sign designs are very largeor are substantially larger in size thanexisting signs, raising questions as tofeasibility, this may require an alternativesign design or an alternative signingapproach.

2.13.1 Comprehension Testing

When signs are developed, they are frequentlytested in a number of ways. Generally they areshown to a committee, usually of traffic engineersor related professionals, who comment on theadequacy of the design. Several alternative designsmay be shown to focus groups to determine driverpreference. They may then be mounted at a testlocation, and any public feedback about them isrecorded before a final design emerges. However,none of these methods ensures that a sign willbe adequately legible for unfamiliar drivers, orthat it will be comprehended by the majority ofdrivers. Traffic engineers have a much greaterfamiliarity with traffic engineering terms, andmessages such as “limited sight distance” whichmay be very meaningful to them, turn out to bepoorly understood by the general public. Focusgroups reveal preference, which may have to dowith attractiveness of a design, but not necessarilywith the ability of individual drivers to comprehenda sign, particularly when it is viewed very briefly asthe driver passes by.

To ensure adequate legibility, the procedure fordetermining letter height described in Section 2.7should be followed. To ensure that the majority ofdrivers understand the sign it should be tested witha representative sample of drivers – on the order of200, with varying age, education and languagebackgrounds. Such studies were carried out toensure the bilingual freeway signs, installed in1993, would be comprehended by the majority ofdrivers.

If a sign must be produced quickly, there may beinsufficient time for a systematic test. In this case,there are some simple steps that will assistengineers to develop a sign likely to be understoodby the general public. The sign, or signs if there arealternative designs, must be shown to a sample ofthe general public. Office employees who arefamiliar with engineering language, even though



they are not themselves engineers, are not idealcandidates because of their “inside knowledge”.A minimum sample would be 24 drivers, and thissample should include approximately one thirdunder age 25, one third aged 26 to 55, and onethird over 55 years. Less experienced rather thanmore experienced drivers are preferable. Whenthere are several alternatives of one sign to betested, it is preferable that each driver be testedwith only one version of the sign, and at least 24drivers be tested for each version.

Sample signs should be drawn up. Each signshould be placed in a background typical of thecontext in which it will be seen, e.g., on a freeway,at an urban intersection. Drivers should see the signfor a few seconds only – this is generally the lengthof time they have to figure out a sign on theroadway. Drivers should then be asked simply whatthe sign means and their answer recorded. Thistechnique is preferable to using a multiple choiceapproach, because it will reveal potential confusion.For example, the SLIPPERY WHEN WET sign isinterpreted by some drivers as WINDING ROADAHEAD. Where fewer than 80% (20/25) of driverstested understand the sign, redesign is required.The drivers’ wrong answers will assist indetermining what aspects of the design need tobe changed.

Where comprehension is poor, and redesign isrequired, it is often the case that only small changesneed be made. For example, the comprehension ofthe SLIPPERY WHEN WET sign was greatlyimproved by merely adding drops symbolizingfalling rain.

The purpose of signs is to convey information todrivers. Signs which are poorly comprehended areineffective. While education campaigns can assistin helping drivers understand a new sign, suchcampaigns are costly, and must be repeated toreach drivers new to the road or new to the area. It

is far more preferable to use a method of signdevelopment and testing that helps ensure that themajority of drivers comprehend the sign withouteducation being required.

2.14 Sign Design Rules

Sections 2.1 to 2.13 addressed general sign designprinciples. This section addresses recommendedrules for detailed sign design (based upon designprinciples outlined above, translated into specificrules). The sign design process is described inSection 2.15, for various kinds of signs.

The recommended rules for sign design included inthis section have been developed over many years,by sign designers at MTO and other roadauthorities. Some of these rules have beenextracted from the King’s Highway Guide SigningPolicy Manual (KHGSPM). These rules werereviewed, and have been updated and expanded forthe purposes of Book 2.

There are many sign design and placementconsiderations/factors, but not all of them directlyaffect the detailed sign design (spatial arrangementof the various sign elements on the face of thesign). Table 2.6 lists the factors affecting detailedsign design.

2.14.1 Standard Signs

For standard signs, there are existing sign designsin the MSL, which prescribe the sign designelements listed above. No further design ofstandard signs is necessary, although it willsometimes be necessary to choose numbers orletters that apply to the situation at hand, such asspeed limits or parking time limits (day of week;hours of day).



Factors Directly Affecting Detailed Sign Design Comments

Sign size

Sign shape Defined by sign type (see Table 2.1)

Colour Defined by sign specification and type

Length of message(s)

Font type and size

Upper/lower case letters,or all upper case

Character spacing (kerning)

Interline spacing

Border space

Maximum number of words

Maximum number of lines

Legend chunking Logical sets of words

Symbols (type and size)

Arrow type and size

Mounting (side/overhead)

Freeway or non-freeway

Factors Indirectly Affecting Detailed Sign Design Comments

Background material (retroreflectivity) Affects legibility at night, and hence may affect signsize; defined by sign specification

Legend material (retroreflectivity) Affects legibility at night, and hence may affect signsize; defined by sign specification

Contrast Defined by background and legend materials;optimum range 4:1 to 15:1; may be up to 100:1

Illumination Affects legibility at night, and hence may affectsign size

Horizontal mounting offset; Vertical mounting offset Affects legibility and hence affects sign size andfont size

Horizontal angle; Vertical angle Affects legibility and hence affects sign size andfont size

Table 2.6 – Factors Affecting Detailed Sign Design



2.14.2 Customized Standard Signs

For customized standard signs (e.g., guide signsbeing the most common example), the rules forsign design need to be applied by the signdesigner.

This section has primary application to directionalguide signs, logo service signs, and TourismOriented Directional Signing (TODS).

Of all the sign types in the OTM, the design ofdirectional guide signs is the most loosely andflexibly defined. As described in Section 2.2(Approaches to Sign Design), directional guidesigns are customized standard signs. They require adesign effort which is intermediate betweenstandard signs with fixed patterns and purpose-designed non-standard signs with no availablepatterns or template. While there are defined typesof directional guide signs, and templates andexamples for each type, the number of variables islarge and the actual design is dependent on thespecific situation. Hence, the examples shown onthe directional guide sign pattern templates willalmost never be built as shown, but will have to beadapted for the situation at hand. One of the mainadvantages of the sign pattern templates fordirectional guide signs is that they show thegeneral appearance of the sign, along with theletter and numeral heights, and specific crowns,markers, symbols, and arrows to be used. Toprovide more assistance to the practitioner,recommended rules for directional guide signdesign are included in this section.

Style of Lettering and Legend Spacing

• Message dimensions are to be determined firstand outside dimensions second. Numeral andletter sizes for principal types of ground-mountedand overhead signs are shown in the Master SignLibrary sign pattern templates for DirectionalGuide Signs. Prescribed numeral and letter sizes

for freeway guide signs appear in Table 2.7.Prescribed numeral and letter sizes for non-freeway guide signs appear in Table 2.8. Whereno suitable examples and sign pattern templatesare shown in the MSL, numeral and letter sizescan also be developed from first principles usingthe method outlined in Section 2.7 (CalculatingLetter Height and Symbol Size).

• The numeral and letter sizes shown in Tables 2.7and 2.8 were originally developed for highwayspeeds (100 km/h for freeways, up to 90 km/hfor non-freeways). Sign sizes derived from suchvalues may be larger than necessary for lowerspeed urban roads (60 km/h or lower). Asdescribed in Section 2.7 (Calculating LetterHeight and Symbol Size), the numeral and lettersizes required are directly proportional to speed.Table 2.8 shows the numeral and letter sizesrequired for each of two posted speed ranges, 70to 90 km/h, and 60 km/h or lower. The sizes forthe 60 km/h or lower speed range in Table 2.8were taken as approximately 75% of those shownfor the 70 to 90 km/h range. If desired, the largersizes may be used for all speed ranges, but forlower speed urban roads (where space for signplacement may be a constraint, for example), thesmaller letter sizes may be used.

• Kerning (the horizontal spacing betweencharacters in a text message, which varies inaccordance with the characters on either side ofthe space) was previously developed manuallywith the use of tables, but is now spacedautomatically in the sign design program.

• Names of places/destinations, streets, andhighways on freeway guide signs (both overheadand ground-mounted) and on non-freewayoverhead guide signs are to be composed oflower-case letters with initial upper-case letters.This also applies to non-freeway ground-mountedguide signs, except that destination names are allupper-case letters.



Notes: * Because of the variability in letter sizes on various signs, the letter sizes on the Sign Pattern Template (SPT) in the MSL takeprecedence over the general guidelines in Table 2.8.

** For ground-mounted signs, and posted speeds of 60 km/h or lower: the reference to the SPTs for directional guide signstaking precedence means that the letter and numeral sizes shown on the SPTs may be reduced by approximately 25%.

Table 2.8 – Letter Sizes for Non-freeway Directional Guide Signs*

Mounting Letter Size

Place Name/ Road/Street Cardinal DistancesDestination Name DirectionOverhead: (Upper/Lower Case) (Upper Case) 1 km (Lower Case)(Upper/Lower Case)Ground-mounted:(Upper Case)

Overhead 340 mm (13.33") 340 mm (13.33") 250 mm (10") 340 mm (13.33") 250 mm (10")UC/LC UC/LC (200 mm (8")

for street names onsignal mast arms)

Ground-mounted Major municipality: 200 mm (8") UC/LC 200 mm (8") 150 mm (6") 115 mm (4.5")(Posted speed 200 mm (8") UC or as shown or as shown or as shown70-90 km/h) Minor municipality: on SPT on SPT on SPT

150 mm (6") UC,or as shown on SPT

Ground-mounted Major municipality 150 mm (6"), 150 mm (6") 115 mm (4.5") 100 mm (4")(Posted speed or place name: UC/LC or as or as shown or as shown60 km/h or lower) 150 mm (6") UC shown on SPT** on SPT** on SPT**

Minor municipalityor place name:115 mm (4.5") UC,or as shown on SPT**

Table 2.7 – Letter Sizes for Freeway Directional Guide Signs

Mounting Letter Size

Place Name/ Road/Street Cardinal DistancesDestination Name Direction(Upper/Lower Case) (Upper/Lower Case) (Upper Case) 1 km (Lower Case)

Overhead 410 mm (16") 410 mm (16") 380 mm (15") 410 mm (16") 300 mm (12")

Ground-mounted 340 mm (13.33") 410 mm (16") 300 mm (12") 340 mm (13.33") 250 mm (10")



• Cardinal directions and other word legends are tobe in upper-case letters; metric unit designations(e.g., km) are to be in lower-case.

• Fonts for traffic signs are available from a varietyof sources. Some sources are listed in Table 2.9

• Figure 2.3 illustrates the guidelines or “rules ofthumb” that generally apply to text guide signs.Dimensions shown are scaleable and are basedon the variable, H, which is equal to the height ofthe largest upper case letters appearing in thedestination names. The height of lower caseletters (called ‘x’ height) appearing in destinationnames, is 0.75 H.

• The vertical space above the top line of text to thetop outer edge of the border (top edge of thesign) should be approximately H, and not lessthan 0.67 H. (Note that there are no inset borderson guide signs which have light legends on darkbackgrounds.)

• The vertical space below the bottom line of text tothe bottom outer edge of the border (bottomedge of the sign) should be approximately H, andnot less than 0.67 H. Additional space may berequired where descenders of lower case lettershang beneath the baseline for upper case text, tovisually balance the clear space below the bottomline of text with the clear space above the top lineof text.

• Vertical spacing between lines of upper-caseletters should be approximately 0.5 to 0.75 H.Where the letter size in adjacent lines of lettersdiffers, the spacing between lines should beapproximately 0.5 to 0.75 times the average ofupper-case letter heights in adjacent lines ofletters. In both cases, additional space may berequired because of ascenders and descenders oflower case letters. For example, if a descender

from an upper row happens to be verticallyaligned with the ascender from the row beneathit, a larger interline spacing should be provided,so that the text is legible.

• The horizontal space from the leftmost edge oftext to the left inner edge of the border should beat least H. An alternate, equivalent definition isthat the space from the leftmost edge of text tothe left outer edge of the border (edge of thesign) should be at least H plus the border. Thecorresponding rule applies to the right side of thesign.

• The minimum horizontal separation between twowords of text should be at least H.

• The minimum horizontal separation between twocolumns of text should be at least 2H.

• The horizontal space between the longest line ofmessage text and the nearest (leftmost) part ofan adjacent arrow to the right of the text shouldbe approximately H. If the arrow is on the leftside of the sign, the horizontal space betweenthe longest line of message text and therightmost part of the adjacent arrow should beapproximately H.

• Horizontal reduction: as noted in Section 2.5.4,when a sign message almost fits onto a signblank, but is slightly too long, the length(s) of theword(s) should be reduced by no more than 10%to make a message fit onto a given blank size.The reduction (compression) should be appliedonly to the words; full spaces between words andbetween words and sign edges should beretained. If the message will not fit on the givensign blank, even with a 10% reduction, then thesign should be made larger; if the sign cannot bemade larger, it should either be redesigned, or amore compressed font should be used (e.g.,Series C rather than Series D).



Gerber’s Graphix

ND Graphic Products Ltd. – Toronto4309 Steeles Avenue WestToronto, ON M3N 1V7tel: (416) 663-6416toll free: 1-888-NDGRAPH (634-7274)fax: (416) 663-5629e-mail: [email protected]: www.ndgraphics.com

ND Graphic Products Ltd. – Ottawa1280 Old Innes Rd., Unit 802Ottawa, ON K1B 5M7tel: (613) 744-7446toll free: 1-888-NDGRAPH (634-7274)fax: (613) 744-0449e-mail: [email protected]: www.ndgraphics.com

ND Graphic Products Ltd – London954 Leathorne StreetLondon, ON N5Z 3M5tel: (519) 686-7870toll free: 1-888-NDGRAPH (634-7274)fax: (519) 686-9972e-mail: [email protected]: www.ndgraphics.com

SignLab

Sign Equipment Canada Ltd.142 Basinview DriveBedford, NS B4A 3J8tel: (902) 835-1910toll free: 1-866-264-5096fax: (902) 484-7506e-mail: [email protected]: www.cadlink.com

Oldham Robinson Integrated Technologies Inc.444 Southcote Rd.,Ancaster, ON L9G 2W3toll free: 1-800-385-7247fax: (905) 648-9639e-mail: [email protected]

[email protected]

Table 2.9 – Suppliers of Sign-making Equipment and Software

ScanVec

Scanvec AmiableInternational Plaza Two, Suite 625Philadelphia, PA 19113 USAtel: (610) 521-6300toll free: 1-800-229-9066fax: (610) 521-0111e-mail: [email protected]: www.ScanvecAmiable.com

FontLab Ltd.PO Box 179Millersville, MD 21108 USAtel: (301) 560-3208toll-free: 1-866-571-5039fax: (301) 560-4155e-mail: [email protected]: www.fontlab.com

(Software and tools for font design, font conversion andfont editing)

FHWA Series Font Distributors

FHWA Signs and Fontstoll-free: 1-866-833-7933e-mail: [email protected]: www.fhwa.ca

DGI

(Distribution)

tel: (905) 846-8667

Adobe® Illustrator®This software package includes some Adobe® fontswhich are used in the OTM.



• Vertical reduction: When a directional guide signmessage almost fits onto a sign blank, but isvertically slightly too large, the interline andvertical edge spacings may be reduced slightly tomake a message fit onto a given blank size. Eachvertical edge spacing and interline spacing ondirectional guide signs may be reduced by up to25 mm. For example, for a two-line sign (oneinterline space and two edge spaces), a 75 mmvertical reduction (compression) would beacceptable, and for a three-line sign, a 100 mmvertical reduction would be acceptable.

Figure 2.3 – Spacing Guidelines for Text on Directional Guide Signs

Note: H = Upper Case Letter HeightB = Width of Border

Letter Size: Metric to Imperial Correlation

Standard sign blanks for regulatory, warning, andtemporary conditions signs are shown in metricdimensions, and all sign pattern templatedimensions are shown in metric dimensions.

As noted in Section 1.4 (Metrication), becauseextruded aluminum panels are manufactured inImperial units of feet and inches, some designersstill design such signs in Imperial dimensions. Notethat the Sign Pattern Templates for extrudedaluminum signs show metric dimensions. Fordesign of extruded aluminum signs in Imperialunits, for the various sign dimensions, the softconversion of 300 mm = 12 inches applies; that is,



a 2400 mm width dimension shown on the SPT isreally 8 feet. However, for design of extrudedaluminum signs in metric units, then a hardconversion between Imperial and metricdimensions needs to be used (12 inches =304.8 mm), except for the letter heights (see Table2.10). If the hard conversion is not used, a metricsign design will not completely cover the panels cutto Imperial lengths.

For letter heights, Table 2.10 provides the Imperialto metric conversion chart.

Limits on Destination Legends

• On any major guide sign, it is preferable to showno more than two destinations or street names,with three as the absolute maximum.Diagrammatic signs may be an exception incertain situations.

• Directional copy, not exceeding three lines, mayinclude symbols, route numbers, arrows, cardinaldirections, and exit instructions. Regardless ofhow the various elements on the sign areassembled, they should not exceed three lines.

• Where two or more signs are placed on the samesupport, it is desirable to limit destinations ornames to one per sign, or to a total of three in thedisplay, to avoid driver information overload.

• Indiscriminate use of supplemental signs shouldbe avoided.

• Where diverging highways provide alternateroutes to the same destination, only one routeshould be posted. (That destination shouldnormally be posted on one route only.)

Abbreviations

• Abbreviations are to be kept to a minimum. In thecase of cardinal directions used with routemarkers on major guide signs, the words“NORTH”, “SOUTH”, “EAST”, and “WEST” are notto be abbreviated.

• Suffix letters may be used, for example, onbranch routes, where a suffix letter is an integralpart of the route designation, or to interchangenumbers that include a suffix letter following theexit number to indicate multi-exit interchanges.(For example, the exits at a freeway interchangemay be numbered 76A and 76B, to show thatthere are two exits, and the correct one must beused for the desired destination or route.)

• The abbreviation for Queen Elizabeth Way is QEW(no periods). It should be used only with a crown.

Imperial Metric(inches) (mm)

3 = 75

4 = 100

5 = 125

6 = 150

7 = 175

8 = 200

10 = 250

12 = 300

13.33 = 340

14 = 360

15 = 380

16 = 410

20 = 510

24 = 610

Table 2.10 – Imperial to MetricConversion Chart for Letter Heights



• Commonly used abbreviations are as follows:

AbbreviationTerm English French

Avenue Ave. Av.Boulevard Blvd. Boul.Circle/Cercle Cir.Concession Con. Conc.County/Comté Cty.Court Ct.Crescent Cr.District Dist. Dist.Drive Dr. Prom.East* E. E.Expressway Expwy.Freeway/Autoroute Fwy. Aut.Fort/Fort Ft.Highway Hwy. Rte.Junction Jct. Jct.Kilometre(s) km kmLake/Lac L. L.Lane Ln.Metre(s) m mNorth* N. N.Place Pl. Pl.Parkway/Promenade Pkwy. Prom.River/Rivière R. Riv.Road Rd. Ch.Saint St./Ste. St./Ste.South* S. S.Square Sq. Pl.Street/Rue St. RueTownship Twp.West* W. O.

* only as part of a destination name, e.g., North Townsville

Symbols, Crowns, Shields, Markers

• Symbols are to be consistent with those usedelsewhere in the OTM. Tab signs (word messages)may be used below symbol designs whererequired.

• Special effort should be made to balance legendand symbol components on the sign to achievemaximum legibility of the symbol.

• The specific size of the crown or shield is selectedfrom the Sign Parts Library (see Section 5.1.4) asa function of road and sign type, and as specifiedon the Sign Pattern Template, if available. The sizeof the numerals in each crown, shield or marker isprovided in the Sign Parts Library.

• Where the Sign Pattern Template does not showa specific size of crown, or where there is no SPT(e.g., diagrammatic signs), the followingguidelines may be used: MC-5 and MC-6 are tobe used for freeway to freeway applications. Themost common use of the MC-6 is for large pull-through overhead signs over multiple lanes (e.g.,401/London). The MC-4 is to be used for otherfreeway signs (both overhead and ground-mounted); if space is tight, the MC-3 may also beused; if space looks too generous, the MC-5 maybe used. Which crown to use is often governedby available space and visual balance andappearance. The MC-3 and MC-2 are generallyused for ground-mounted signs on non-freeways.

• If a crown or marker is used to apply to a singleline of adjacent text, the line of text should becentred vertically relative to the numerals in thecrown or marker. If a crown or marker is used toapply to two (or three) lines of adjacent text, thelines of text should follow the usual interlinespacing rules, and the crown or marker should bevertically balanced (centred) beside them.

• Figure 2.4 illustrates the guidelines or “rules ofthumb” that generally apply to guide signs witharrows and crowns/markers/shields. Guidelinesfor clear horizontal space to the left of the legendand to the right of the legend are the same as for



text guide signs, as discussed with reference toFigure 2.3. (The legend includes all text, arrows,crowns, markers, shields, and other symbols/graphics appearing on the sign.)

• Guidelines for interline spacing of text are thesame as for text guide signs, as discussed forFigure 2.3 above.

• The vertical space above the top of the crown,marker, or shield to the top outer edge of theborder (edge of sign) should be at least equal totwice the border width. That is, the clear spacebetween the top of the crown, marker, or shieldand the top inner edge of the border should be atleast equal to the border width. Similarly, thevertical space from the bottom of the crown,

marker or shield to the bottom outer edge of thesign border (where the crown is in the bottomline) should be at least equal to twice the borderwidth. That is, the clear space between thebottom of the crown, marker, or shield and thebottom inner edge of the border should be atleast equal to the border width. The vertical spacefrom the bottom of the crown to the next line oftext should be approximately 0.5 H.

• The clear horizontal space between two markersor two shields on the same line, or between amarker and a shield on the same line should beat least H, measured at their nearest points.

Figure 2.4 – Spacing Guidelines for Text on Directional Guide Signs with Arrows, Crowns & Shields

Note: H = Largest Upper Case Letter HeightB = Width of Border



Figure 2.6 – Parking Sign Arrows

Figure 2.5 – Ahead ArrowsArrows

The specific size of the arrow is selected from theSign Parts Library, as specified on the Sign PatternTemplate for that particular sign (see Section 5.1.4and the MSL).

Dimensions of arrows for use on guide signs areshown in the Sign Parts Library. Specificapplications of arrows are as follows:

• Ahead ArrowsShort, upward pointing “ahead arrows” are usedon some standard regulatory, warning, andtemporary conditions signs. These arrows arealready included on the standard sign patterntemplates for these signs. They are also includedin the Sign Parts Library if needed for other signs,e.g., non-standard signs. They are not used ondirectional guide signs. See Figure 2.5.

• Parking Sign ArrowsShort, horizontal arrows are used on parkingrestriction and permitted parking signs, and arealready included on the standard sign patterntemplates for these regulatory signs. They arealso included in the Sign Parts Library if neededfor other signs. See Figure 2.6. They are not usedon directional guide signs.

• Overhead Advance Sign ArrowsWhen used on overhead advance direction signs,upward pointing straight arrows and upwardcurving arrows should be used to represent thethrough road and the lane(s) exiting from thethrough road, respectively (Freeway AdvanceArrows). See Figure 2.7. The arrows must belocated on the side of the sign closest to the exitlane. Various combinations of these arrows, withassociated exit lane designations, are included inthe Sign Parts Library, and are titled “FreewayAdvance Arrows” (FAA) (formerly called “RevisedFreeway Signing System“ or “RFSS”).

Placement of Overhead Advance Sign Arrows:The bottom of the arrow(s) is lined up relative tothe bottom of the sign as shown in the Sign PartsLibrary (dimensions are shown).

The horizontal distance from the right edge of theblack/yellow exit panel to the right edge of thesign (and hence the arrow placement relative tothe right edge of the sign) is also shown in theSign Parts Library.

The horizontal distance from the left edge of theblack/yellow exit panel (or, if the exit panelapplies only to the right arrow, from the left edgeof the left arrow shaft) to the adjacent lines ofdestination text should be at least 2H.



Figure 2.7 – Overhead Advance Sign Arrows



As shown on the FAA arrow blocks in the SPL,for a nominal 2100 mm (7 foot, actual 2133.6mm) sign, the top spacing (from the top of thearrow to the top edge of the sign) is shown as175 mm (7") or 200 mm (8"), depending on thearrow or arrows depicted. Again, for the 7 footsign, the bottom spacing (from the bottom of theexit panel to the bottom edge of the sign) isshown as 300 mm (12"). If the sign is 8 feet or9 feet high, then half the additional height isadded to the top spacing and the bottomspacing. Hence, on a 7 foot sign, the top andbottom spacings are 175 mm (7") and 300 mm(12") respectively, on an 8 foot sign, they are330 mm (13") and 460 mm (18") respectively,and on a 9 foot sign, they are 485 mm (19") and610 mm (24") respectively.

• Downward ArrowsWhen used with overhead guide signs todesignate the use of specific traffic lanes fordrivers bound for a destination, route, or exit, thearrows must be downward pointing. In thesecases, a separate arrow should be centred overeach lane serving the destination appearing onthe sign. Where space does not permit this(e.g., cantilever signs), downward sloping arrowsmay be used. There is one type of downwardarrow (Lane Designation Arrow Tab), as shownin the Parts File in the Sign Parts Library. SeeFigure 2.8.

Downward arrows are required on:

• exit signs to indicate the number and locationof exiting lanes;

• over all lanes where freeway-to-freeway splitsoccur;

• over all lanes where signs indicate the majorthrough highway (e.g., 401 East or 401 West);

• over all lanes where express/collector begins.

Where downward arrows are used over all lanes(e.g., signs indicating 401 East or 401 West),they are white arrows used on the blue or greenbackground, positioned over the centre of thelane to which they apply. Where downwardarrows are used to indicate exit lanes, they areblack arrows on a yellow background panelalong the bottom side of the sign. See FAA PartsFile in the SPL. In such cases, because thelegend is dark (black) against a lighter (yellow)background, both a yellow outer border and ablack inset border are used for this lower panel.Both the yellow outer border and the black insetborder are 37.5 mm (1.5") wide. The spacingfrom the bottom point of the arrow to thebottom edge of the sign should be 125 mm (5"),leaving a clear space of 50 mm (2") betweenthe bottom point of the arrow and the insetborder. The yellow panel itself is 600 mm (24")high times the width of the sign, and thespacing between the top of the downward arrowand the top of the yellow panel should be atleast 37.5 mm (1.5").

Downward arrows are not required on advanceor pre-advance signs indicating, e.g.,“Morningside 1 km, Whites Road 3 km, etc.”

Figure 2.8 – Downward Arrows



• Advance and Exit ArrowsThe use of advance and exit arrows issummarized in Table 2.11. When used on ground-mounted exit direction signs, arrows are to beupward slanting at an angle representative of thealignment of the exit roadway (or, onnon-freeways, pointing left or right as the casemay be), and they are to be located on theappropriate side of the sign corresponding to theside of the exit. These arrows are called Gerberarrows. The arrows to be used are as shown onthe Sign Pattern Template, and are to be centredvertically. Three multi-purpose Gerber arrows areincluded in the Sign Parts Library, which can beadjusted to match the specified arrow on the SPT.See Figure 2.9. These arrows have the generaldesignation A x-y or A x-y-z, where x is the widthof the arrow head, y is the length of the arrowshaft adjacent to the arrow head, and z is thelength of the arrow shaft tail connected at anangle to arrow shaft y. The shaft width is notdirectly shown in the SPL, but is about 38% ofthe width of the arrow head (x). When thesearrows in the SPL are used and scaled up ordown, the relative proportions of the arrow headwidth and the shaft width will be automaticallymaintained.

Where the size of arrow is not specified or is notknown for a given sign, as a rule of thumb, thewidth of the arrow head should be equal to theheight of the largest letter on the sign.

• Diagrammatic ArrowsDiagrammatic arrows are used on diagrammaticsigns. A selected set of these arrows is includedin the Sign Parts Library. See example in Figure2.10. If one of these arrows in the SPL does notfit the situation at hand, the sign designer mayneed to draw a custom-designed diagrammaticarrow. On overhead signs, these arrows show thelane markings. On ground-mounted signs, they donot show the lane markings.

The minimum horizontal separation between a lineof text and the nearest (leftmost or rightmost, asthe case may be) horizontal part of an adjacentarrow should be approximately H. However, asnoted above, the minimum separation between aline of text and a block of exit arrow(s) and EXITpanels should be at least 2H.

Advance Guide Sign* Exit Guide Sign

Freeway: Overhead Yes YesFAA arrow(s), or Diagrammatic arrows Downward arrow(s)

Freeway: Ground-mounted Usually No Yes(Gerber arrows if used) Gerber arrows

Non-freeway: Overhead Yes YesFAA arrow(s) Downward arrow(s)

Non-freeway: Ground-mounted Yes YesGerber arrows Gerber arrows

Table 2.11 – Use of Arrows on Advance and Exit Guide Signs

* The Advance Guide Signs referred to in the table are generally within 60-100 m (non-freeways) or within 300-500 m(freeways) of the exit. Advance Guide Signs further upstream (typically 1 to 6 km) name the exit(s), but do not have arrows.



Figure 2.9 – Advance and Exit Arrows

Note: For the correct scale use the arrow head size, i.e., as the base dimension.

Figure 2.10 – Examples of Diagrammatic Arrows



Figure 2.12DISTANCE ASSURANCE Sign (Gf-12)

Figure 2.11ADVANCE GUIDE Sign (Gf-1)

Centring and Justification Guidelines

In addition to the spacing and arrow selectionguidelines outlined above, there are guidelines forcentring and justifying components of the legendfor visual balance and clarity of the sign message.The following centring/justification guidelines applyto guide signs:

• If the sign consists of one column of text only(e.g., ADVANCE GUIDE sign (Gf-1)), the lines oftext should be all horizontally centred about thecentral vertical axis of the sign face. SeeFigure 2.11.

• If the sign consists of two columns of text only(e.g., DISTANCE ASSURANCE sign (Gf-12),INTERCHANGE SEQUENCE sign (Gf-5)), the leftcolumn is left-justified and the right column isright-justified. See Figure 2.12.

• The text and graphic components of the signmessage should be visually balanced to supportmaximum legibility. It may be necessary to fit thesign and message to the horizontal width of thesign (for example, over a specific number oflanes). Minimum spacings may be increased inorder to achieve better visual appearance andmessage positioning.

• If the cardinal direction appears beside the crownor marker (e.g., TURN-OFF – RIGHT TURN sign(Gr-2)), the cardinal direction text in all upper caseletters should be centred vertically relative to thenumerals in the crown or marker. In this situation,the destination name should be centred beneaththe line of text consisting of crown/marker andcardinal direction.

• In general, it is preferable on signs such as Gr-1(CHANNELIZING – RIGHT TURN sign), Gr-2, andGr-3 (CHANNELIZING – LEFT TURN sign), to havethe cardinal direction beside the crown/markeron the same line, with the destination namecentred beneath the line of text consisting of

crown/marker and cardinal direction. See Figures2.13 to 2.16. On Gr-1, Gr-2, and Gr-3, the arrowshould be positioned so as to be toward one endof the sign, and vertically centred on the full signheight. Gr-4 should show the horizontal left arrowunderneath the legend block of the crown/marker, cardinal direction, and destination name.

• If horizontal space does not permit the designapproach outlined in the point above, the cardinaldirection can appear below the crown or marker.The cardinal direction text should be centredhorizontally beneath the crown or marker. In thissituation, the destination name should be centredacross the width of the sign.



Sign Border Sizing and Cornering

• Metal sign blanks should have both roundedcorners and rounded borders.

• Blanks 890 mm or less in dimension shouldhave a blank corner radius of 40 mm.

• Blanks 900 mm or greater in dimension shouldhave a blank corner radius of 50 mm.

• Plywood sign blanks should have both squaredcorners and squared borders.

• Aluminum extrusion signs should have squaredcorners and may have squared or roundedborders.

Where an inset border is used, the inset sign bordermust be the same colour as the legend, and theouter border must be the same colour as the signbackground. An inset border is not used on guidesigns which consist of a light-coloured legend on adark-coloured background (except for blackdownward arrows on an overhead yellow exit lanepanel, where this panel has an inset and an outerborder).

The dimensions shown in Tables 2.12, 2.13 and2.14 for sign border sizing and cornering, for metalblanks, plywood blanks, and aluminum extrusionsrespectively, are given in reference to the radiiillustrated in Figure 2.17.

Figure 2.16TURN OFF – LEFT TURN Sign (Gr-4)

Figure 2.15CHANNELIZING – LEFT TURN Sign (Gr-3)

Figure 2.14TURN OFF – RIGHT TURN Sign (Gr-2)

Figure 2.13CHANNELIZING – RIGHT TURN Sign (Gr-1)



Smaller Inset Border Corner Radius Edge Border Corner RadiusSign Thickness

Dimension Edge Thickness R1 R2 R3 R1 R4

up to 200 7.5 7.5 20 12.5 5 7.5 20 12.5

300 10 10 30 20 10 10 30 20

450 12.5 12.5 40 27.5 15 12.5 40 27.5

600 12.5 12.5 40 27.5 15 12.5 40 27.5

750 12.5 12.5 40 27.5 15 12.5 40 27.5

900 20 20 50 30 10 20 50 30

Table 2.12 – Sign Border and Cornering Dimensions: Metal Blanks(all dimensions in millimetres (mm))

* Some road authorities use rounded corners and borders; some others use squared corners with rounded borders.

Table 2.14 – Sign Border and Cornering Dimensions: Aluminum Extrusion(all dimensions in millimetres (mm))


Dimension Edge Thickness R1 R2 R3 B R1 R4

ALL 35 35 100** 50 15 50 100** 50

** Aluminum extrusion blanks are cut with squared corners. Many road authorities use squared borders.If rounded borders are used, use R1=100.

Table 2.13 – Sign Border and Cornering Dimensions: Plywood Blanks(all dimensions in millimetres (mm))


Dimension Edge Thickness R1 R2 R3 B R1 R4

200 20 20 20

300 20 20 20

450 20 20 Plywood 20 Plywood

600 25 25 Squared 25 Squared

750 25 25 Corners* 25 Corners*

900 25 25 25

1200 25 25 25



R1 Blank corner radius defined by blank size

R2 Outside border radius defined as R1 less Edge measurement

R3 Inside border radius defined as R2 less Thickness measurement

R4 Inside border radius defined as R1 less Thickness measurement

Figure 2.17 – Sign Border and Corner Radii

Size of Guide Signs

• The size of guide signs (and other customizedstandard signs and non-standard signs) isdetermined from the length of message and thesize of lettering necessary for proper legibility.

• Overhead and large ground-mounted signs aregenerally designed to have widths of even,nominal 600 mm (actual 2 foot) increments.Extrusion lengths in even numbers of feet are themost common. Of lengths in odd numbers offeet, the most common extrusions are 2.743 m(9 feet), 3.352 m (11 feet) and 4.572 m (15 feet).Aluminum extrusions can be ordered in almostany sign width (extrusion length).

• Under some circumstances (especially foroverhead signs), available space is the controllingfactor. A sign mounted over a roadway lane mayhave to be limited in horizontal dimensions to thewidth of the lane, so that another sign may beplaced over an adjacent lane.

• Under other circumstances, where lanedesignation arrows are used, a minimum width ofoverhead signs is required, for positive driverguidance. Minimum sign widths for lanedesignation arrows centred over 3.65 m (12 foot)lanes should be as follows:

Sign centred over 2 lanes 4.9 m (16 ft)Sign centred over 3 lanes 8.5 m (28 ft)Sign centred over 4 lanes 12.2 m (40 ft)

• The maximum size (area) for the overhead signson a single overhead sign structure is limited to42 square metres. The maximum height of anoverhead sign is 2.75 m. The maximum heightand width for ground-mounted signs aregenerally about 3.00 m and 4.80 m respectively.For both overhead and ground-mounted signs,available space may limit the area, width, orheight of the sign to smaller values.



Colour

• The sign background and legend colours are tobe used as shown on the Sign Pattern Templates.

• In the case of an express-collector type facility,the background colour for guide signs oncollector lanes is to be reflective blue, whereasthe reflective green background is used for guidesigns on express lanes.

• The standard print colour specifications forOntario traffic signs are shown in Table 2.15.Colour specifications for sign sheeting aredefined in the ASTM D 4956-01a specification(daylight luminance and chromaticitycoordinates).

Overhead Signs

Overhead signs are beneficial on many roads,especially multi-lane roads, because they afford alldrivers a view of the directional information, butthey are more costly than ground-mounted signs.

Various factors may justify the installation ofoverhead directional guide signs. They are notalways definable in specific numerical terms, butthe following conditions deserve consideration:

• Freeway configuration, especially urban freeways• Three or more lanes in each direction• Traffic volume at or near capacity• Complex interchange design• High traffic speeds• Closely-spaced interchanges• Restricted sight distance• Multi-lane exits• Large percentage of trucks• Consistency of sign message location through a

series of interchanges• Junction of a major route with another freeway• Left exit• Insufficient space for ground-mounted signs• Background street lighting• Road authority policy

Spot Colour Process Colour

Colour Name Pantone® Matching System Cyan Magenta Yellow Black(PMS) (C) (M) (Y) (K)

Black 426 0 0 0 100

Blue 294 100 56 0 18.5

Brown 469 0 51 94 60

Chartreuse* 389 18.5 0 83 0

Green 342 100 0 69 43

Orange 152 0 51 100 0

Red 187 0 91 72 23.5

White N/A 0 0 0 0

Yellow 116 0 15 94 0

Table 2.15 – Standard Print Colour Specifications for Ontario Traffic Signs

* Another term for chartreuse is ‘strong yellow-green’.



Differences between Overheadand Ground-mounted Signs

The sign design rules for letter and numeral size foroverhead and ground-mounted directional guidesigns are summarized in Table 2.7 (Freeways) andTable 2.8 (Non-freeways). Other sign design rulesfor overhead and ground-mounted directional guidesigns are basically the same except:

• For overhead signs and ground-mounted freewaysigns, use Series E(m) font. For non-freewayground-mounted signs, use Series E font or, asspecified on the Sign Pattern Templates, evenSeries D or C.

• On overhead diagrammatic signs, show lanemarkings. On ground-mounted diagrammaticsigns, do not show lane markings.

2.14.3 Diagrammatic Guide Signs

Diagrammatic guide signs are a special case ofcustomized standard signs.

Diagrammatic guide signs have proved to beeffective for some types of overhead freewayinterchange signing, e.g., destination signing inadvance of a complex or unusual freewayinterchange. Diagrammatic signs work well forconveying information about unexpected or unusualmanoeuvres which can be displayed with a simplegraphic. They are recommended for signing driverexpectation violations, such as a left exit or somefreeway-to-freeway interchange splits (see Figure2.18). However, diagrammatic signs sometimes areoverused, or are used where the information couldbe provided in a simpler manner. They are notrecommended for signing situations that are eithervery simple and more efficiently handled throughconventional interchange signs (e.g., single righteither/or exit lane) or so complex that a graphicalrepresentation would confuse drivers (e.g., double

lane drop followed by a fork (multiple split ramp)).For more information on the functionality ofdiagrammatic guide signs, see Book 8 (Directionaland Information Signs) (under development).

Usage Location

• Graphics on a diagrammatic sign display theapproximate geometry of the intersection alongwith essential directional information.

• Diagrammatic messages may be used aspre-advance guide signs to convey directionalinformation some distance in advance of theinterchange or freeway exit (not less than 1 kmin advance of the gore area and not at thebeginning of a deceleration lane taper).

• Diagrammatic signs should be used assupplementary signs; they are not to replacestandard Advance and Turn Off signs.

• Generally, diagrammatic messages should belimited to unexpected or unusual manoeuvresthat can be displayed with a simple graphic.

• These signs may be considered for use atinterchanges with the following types of design:

• left exit• left exit in combination with single right exit• major fork• two right exits, where there is insufficient space

for conventional signing.

Figure 2.18 – Example ofDiagrammatic Guide Sign



• Each location is to be evaluated on its ownneeds. The mere fulfillment of the aboveconditions does not justify the installation ofthese signs.

Usage not Recommended

Diagrammatic signs are not recommended at thefollowing types of interchanges:

• single right exits, including diamond interchanges• common cloverleaf interchanges• interchanges with collector-distributors• interchanges with double lane drops followed by

a fork (multiple split ramp)• very complex interchanges (where it is difficult to

design graphics that will be simple and yet willaccurately portray the geometry of theinterchange).

Design Rules

The following design rules apply to diagrammaticsigns:

• The graphic component should be simple andportray only what is necessary for the driver tounderstand the required exit manoeuvre relativeto the main road. Additional details depicting theexiting path characteristics beyond the exit pointshould be avoided.

• Wherever possible, route symbols or numbers,rather than route names, should be used toprovide exiting and destination information.

• Diagrammatic arrows are used on diagrammaticsigns. A selected set of these arrows is includedin the Sign Parts Library. If one of these arrows inthe SPL does not fit the situation at hand, thesign designer may need to draw a custom-designed diagrammatic arrow. On overheadsigns, these arrows show the lane markings. Onground-mounted signs, they do not show the lanemarkings, because of space limitations.

• The spacing rules of sign message arounddiagrammatic arrows are somewhat different thanfor non-diagrammatic arrows. The horizontalspacing between sign text (words or crowns andmarkers) and the nearest point on thediagrammatic arrow (on the same horizontal line)should be at least H. Depending on theconfiguration of the diagrammatic arrow, anotheruseful check is to ensure that the nearer end ofthe longest text line is aligned horizontally withthe left or right extremity of the arrow, as the casemay be (that is, it is not closer to the arrow thanthis). This helps to maintain clarity by ensuringthat the text blocks do not encroach too closelyinto the arrow space. This last check may not beapplicable for some unusually shapeddiagrammatic arrows.

• The information on the sign should be limited tothree arrows with not more than one destinationper directional arrow. In the exceptional casewhere two through route symbols are required,the second symbol should be positioned besidethe first.

• Deceleration lanes should not be shown on thegraphics components.

• The graphic components should be designed sothat the through route is the visually dominantportion of the graphic (except for a major fork).

• On overhead signs, lane lines must be includedwhere applicable on the graphics. Lane markingson freeway diagrammatic signs should be 50 mmwide.

• The stem length of the arrow must be sufficientlylong to depict the lane configuration upstream ofthe split. The stem of the arrow representing theroad upstream of the split should be at least 25percent of the total height of the graphiccomponent.



• Destination information must be clearly related tothe appropriate arrowhead.

• Exit information text related to a given routemarker should not be placed so that it extendsabove the top of the route symbol, but this textshould be below it or to the side.

• Where an off-ramp is tangential to the beginningof a curve in the through route, a curved arrowshould be used to indicate the through route.

• Letter size standards should not be reduced ondiagrammatic signs. In many cases, the additionof graphic components requires a substantialincrease in the overall size of the sign panel.

2.14.4 Non-standard Signs

For non-standard signs, the rules for sign designneed to be applied by the sign designer, as anexisting sign or pattern cannot be used as is. If thenon-standard sign is like a directional guide sign innature, the rules as outlined in Sections 2.14.2 and2.14.3 should be used.

Many non-standard signs are more like standardsigns in nature, such as warning or temporaryconditions signs, where the shape and relativelysmall size are more restrictive. A common type ofnon-standard sign is a new warning sign requiredby municipalities, other road authorities, orcontractors for special purposes. In such cases, therules as outlined below should be used.

Non-standard signs are signs for which there is nosign pattern template, and the size and messageare designed for a specific purpose (see Section2.2). If a new signing need arises, it is desirablethat such a non-standard sign be designed fromfirst principles and tested. Once it is designed, andproven effective, it should be considered foraddition to the appropriate Books of the OTM, so

that other jurisdictions with the same needs candraw upon the existing design and so uniformity insigning is encouraged. At this point, the sign wouldbecome a standard sign with an existing pattern.See also Section 2.13 (Process for Assessing andRevising Sign Designs).

The following guidelines and rules apply to thedesign of non-standard signs:

• Consult the OTM and other North Americansigning manuals to determine whether signs witha similar purpose exist, from which the new non-standard sign can be adapted.

• Apply the existing sign colour and sign shapecodes (see Section 2.4) to reflect the function ofthe new sign.

• Determine if a symbol alone or in combinationwith text can convey the sign message. If asymbol is to be used, design the symbolaccording to the guidelines provided in Section2.6. Graphics and symbols should be kept simple;unnecessary details cannot be read at speed. Donot over-complicate or overuse graphics orsymbols.

• If text is to be shown on the sign, develop asimple, concise message that minimizes thenumber of words while maintainingcomprehensibility. Follow the guidelines for fontand upper/mixed case provided in Section 2.5(Text Legends). Be careful to avoid informationoverload (too much information crowded onto asmall sign with small fonts).

• For signs including text, determine whether abilingual sign is required, decide on the overallsigning approach from the options described inSection 2.13 (Process for Assessing and RevisingSign Designs), and develop bilingual textmessages.



• Calculate the letter height and/or symbol size forthe sign using the process described in Section2.7 (Calculating Letter Height and Symbol Size).Alternatively, use a font size shown on the SignPattern Template for a similar type of standardsign.

• Draft the layout of the sign, using similarapproaches for interline spacing, borders, clearspaces and other layout guidelines as thoseshown on similar standard signs.

• Determine the requirements for retroreflectivesheeting based on the functionality of the signand the guidelines provided in Section 2.9(Reflectorization and Illumination) and Section 3(Sign Materials).

• View the sign design from a suitable distance.Often a design that looks clear and readable onthe desk or computer screen does not appear soat a distance.

Using the above guidelines, develop alternativelayouts for comprehension testing. For example, atext only version, a symbols plus text version,versions using different symbols, etc., could bedeveloped. The comprehension testing shouldfollow the process outlined in Section 2.13.1(Comprehension Testing).

2.15 Sign Design Process

The sign design process is illustrated in FlowchartA, made up of four interconnected parts(Flowcharts A.1, A.2, A.3 and A.4). Flowchart Aillustrates the sign design steps to be taken forstandard signs, customized standard signs, andnon-standard signs. It also illustrates the steps tobe taken if a bilingual or French version of a signneeds to be developed. The sign design processdescribed in this section is not intended to be

prescriptive, but rather to provide a useable guidefor those who find it beneficial. Other approachesor sequences may be used, provided the endproduct meets the requirements.

2.15.1 Sign Design Flowchartand Description

Flowchart A was conceived as a single large chart,but has been divided into several separate piecesfor ease of publishing. Following the processdescribed here, the chart is entered at the top,marked “Start.” The first check is whether or notthis is a bilingual or French language sign. If it is,one goes to the “BLF” circle, and proceeds to thelast sheet (Flowchart A.4). After determining thecharacteristics of the sign, the process brings oneback into the mainstream part of the flowchart. Thenext check is to identify the sign classification, andthen to follow one of three streams: standard sign,customized standard sign, or non-standard sign.Each stream leads the user through the sign designprocess, ending with the export of the sign designto the cutting or printing software, and hence tothe sign fabrication process, described in Section 4and illustrated in Flowchart B and its sub-charts.



Flowchart A.1 – Sign Design Process



Flowchart A.2 – Sign Design Process – Customized Standard Sign Design



Flowchart A.3 – Sign Design Process – Standard Sign Design



Flowchart A.4 – Sign Design Process – Bilingual or French Language Signs



2.15.2 Application of Sign Design Process(Examples)

The application of the sign design process isillustrated here by use of examples. Some acronymsused in this section are: Master Sign Library (MSL);Sign Pattern Template (SPT); and Sign Parts Library(SPL).

Example 1

Figure 2.19 – Standard SignMAXIMUM SPEED (Rb-1)

Location data: Required sign is 50 km/h, size is600 mm x 750 mm.

Follow the steps outlined below.

(1) Is a bilingual or French language signrequired? No.

(2) Identify class of sign: Standard sign.

(3) Required sign is Rb-1; required size is600 mm x 750 mm.

(4) Locate Rb-1 Sign Pattern Template in MSL.

(5) Is this the right template for the desired size?Yes.

(6) Do the numerals on the Sign Pattern Templateneed to be changed? No.

(7) Do borders have to be modified to fit borderrules? No.

(8) Use cut image for Rb-1, export for scaling upin cutting or printing software, either byapplying scale factor from scale image or byapplying absolute sign dimensions to thesign. See Section 4 (Sign Fabrication).

Example 2

Figure 2.20 – Standard SignMAXIMUM SPEED BEGINS (Rb-2)

Location data: Posted speed is 60 km/h; two-laneroad; no space constraints; ground-mounted sign;good vertical alignment; somewhat restrictedhorizontal alignment. These are the first 60 km/hsigns after a long section of road that has had 80km/h posted speed. To draw motorists’ attention tothe change in speed, an oversize MAXIMUMSPEED AHEAD sign and an oversize MAXIMUMSPEED BEGINS sign will be used. Note that theMSL does not contain standard oversize versions ofthese signs, so special oversize versions will have tobe created.

Follow the steps outlined below.




(2) Identify class of sign: Standard sign.

(3) Required sign is Rb-2; standard size is600 mm x 900 mm; this special oversizesign will be 900 mm x 1500 mm (there is nostandard sign blank of 900 mm x 1350 mm,which would maintain the same proportions).

(4) Locate Rb-2 Sign Pattern Template in MSL.

(5) Is this the right template for the desired size?No, because the proportions of the desiredsign are 3:5 rather than 2:3. But no othertemplate is given for this sign; this one willneed to be adapted. Sign blank will be B-37,plywood. Create new image file, of desireddimensions 900 mm x 1500 mm. The lettersizes should be increased by 50% (900/600), and the vertical spaces should beincreased so that the letters and numerals areproportionately spaced verticallyapproximately as shown on the original Rb-2template.

(6) Do the numerals on the Sign Pattern Templateneed to be changed? Yes, from 50 to 60.Remove the ‘5’ and replace it with a ‘6’ usingthe same font.

(7) Do borders have to be modified to fit borderrules? Yes. At this size, this is a plywood sign.From Table 2.13, the outer border (edge) is 25mm and the inner border (thickness) is 25mm, and the borders and corners are square,not rounded.

(8) Use adapted image file for oversize Rb-2, usethis as cut image and export for scaling up incutting or printing software.

Example 3

Figure 2.21 – Customized Standard SignTURN-OFF RIGHT TURN (Gr-2)

Location data: Posted speed is 70 km/h;municipal two-lane road (one lane each direction);no space constraints; ground-mounted sign; goodvertical and horizontal alignment.

Follow the steps outlined below:


(2) Identify class of sign: Directional guide sign, acustomized standard sign.

(3) Required sign is Gr-2; nominal size is900 mm x 2100 or 2400 mm. Actual sizeneeds to be determined through the designprocess.

(4) Locate Gr-2 Sign Pattern Template in MSL.

(5) Is this the right example for this sign? Yes.

(6) Is this a ground-mounted or overhead sign?Ground-mounted.

(7) Is this a freeway or non-freeway? Non-freeway.

(8) Review and draw upon the sign design rulesfor non-freeway, ground-mounted signs.

(9) Finalize the sign message including anyabbreviations.



(10) Is this a diagrammatic sign? No.

(11) Determine font, letter size, and case from SignPattern Template. The font is Series D, theletter size is 200 mm, and the text is all uppercase.

(12) Type out all text in Series D in sign designprogram.

(13) Determine arrows, crowns, symbols to beused (type and size) from the SPT and theSign Parts Library in MSL. The crown is anMC-2 crown and the arrow is an A200-300.

(14) Determine colours to be used (from SPT ifavailable, or sign class).

(15) Insert horizontal spacing and justificationbetween text blocks and symbols, arrows, etc.The specified MC-2 crown is 432 mm highand 552 mm wide (from Sign Parts Library),with a numeral text size of 250 mm. Theheight of the largest letter (H) is 200 mm. Theword ‘EAST’ is 606 mm wide and the word‘BROCKVILLE’ is 1466 mm wide. Theminimum top text line length (401 EAST) is1358 mm (552 + 200 + 606). The minimumbottom text line length (BROCKVILLE) is1466 mm. The bottom line is to be centredunder the top line, hence the combined textblock width (both lines) will be 1466 mm. Theminimum space between the combined textblock and the arrow is 200 mm. The arrowwidth is 374 mm. The minimum marginspacing on the left, between the left edge ofthe text block and the left edge of the sign is200 mm plus the border width. The minimummargin spacing on the right, between thearrow and the right edge of the sign is also200 mm plus the border width. If the signsize can be kept below 1200 mm x2400 mm, it will be a plywood sign, and the

edge border width will be 25 mm. If the signsize is larger than this, in either dimension, itwill be an aluminum extrusion sign, and theedge border width will be 50 mm.

(16) Determine the minimum width of the sign,which is the length of the longest lineincluding text, symbols, spaces, margins, andborders. The minimum width (excludingborders) is 200 + 1466 + 200 + 374 + 200= 2440 mm. On a plywood sign, with 25 mmborders, the total minimum width would be2440 + 25 + 25 = 2490 mm. This is widerthan the largest plywood size of 2400. Nowthe question becomes: can the sign becompressed within the rules (10%compression), and still fit on a 2400 mmplywood sign (a compression of 90 mm), oris it necessary to use an aluminum extrusionsign?

When the sign is compressed horizontally, thecompression applies principally to the textand should not exceed 10%. The softwarecompression tool is used to execute thecompression, either to fit a given space or bya given percentage. A 6.1% compressionapplied to the word BROCKVILLE (1466 mm)would reduce it by 90 mm for a width of1376 mm. The top line (1358 mm) would notneed to be compressed. A plywood signcould be used for this sign (based so far onhorizontal dimensions only). As a check, thetotal width is 25 + 200 + 1376 + 200 + 374+ 200 + 25 = 2400 mm.

The decision might also be made not tocompress the sign horizontally, but to use analuminum extrusion sign. For aluminumextrusion signs, the border width is 50 mm,hence the total minimum sign width wouldbe 2490 + 50 + 50 = 2590 mm. The nextlarger aluminum extrusion sign size is 9 feetor 2743 mm. To fit on this wider sign, thehorizontal spaces on the sign (margins and



space from text block to arrow) are adjustedupwards proportionately, in this case by(2743 – 2590)/3 = 153/3 = 51 mm. Whenan aluminum extrusion sign is used, it isnecessary to develop the sign designdimensions so that it exactly fits the Imperialdimensions of the sign.

(17) Insert vertical spacing between lines andsymbols, etc. Check the SPT. The minimumspacing between the lines of text should be0.5 to 0.75H (H is the largest letter size),which is a minimum of 100 mm. The spacingbetween the bottom of the crown and thelower line of text should be approximately0.5H or 100 mm.

(18) Determine the minimum height of the sign,considering the height of all elements, withreference to Step 17. Considering the lines oftext first, the minimum vertical dimensionshould be 133 + 200 + 100 + 200 + 133= 766 mm. Considering the crown and thelower line of text, the minimum verticaldimension should be 50 + 432 + 100 + 200+ 133 = 915 mm. This is slightly more thanthe 900 mm shown on the SPT. From thesign design rules, for a two-line sign, a verticalcompression of up to 75 mm is acceptable,which is more than sufficient to fit the sign ona plywood blank. The bottom margin and theinterline spacing are reduced by 8 and 7 mmrespectively, so the overall minimum verticaldimensions will be 50 + 432 + 93 + 200 +125 = 900 mm.

(19) Add the borders to the sign design, 25 mmwide and squared corners, as specified inTable 2.12.

(20) Check to see that the sign design appearsvisually balanced. If it is not, make minorreadjustments. If it is satisfactory, move to thenext step.

(21) Check whether the sign width violates anyphysical width constraints. It does not.Location data indicated there were no spaceconstraints.

(22) This is not an overhead sign, hence maximumsign area and sign height constraints do notapply.

(23) Use adapted image file for this sign, use thisas cut image and export for scaling up incutting or printing software.

Example 4

Figure 2.22 – Customized Standard SignADVANCE TURN-OFF RIGHT TURN (Gf-22)

Location data: Posted speed is 100 km/h; freeway(two lanes each direction); overhead sign; goodvertical and horizontal alignment.


(1) Is a bilingual or French language signrequired? No; the exit panel will say EXIT, notEXIT/SORTIE.


(3) Required sign is Gf-22; nominal size is2100 mm (7 feet) x variable. Actual sizeneeds to be determined through the designprocess.

(4) Locate Gf-22 Sign Pattern Template in MSL.




(6) Is this a ground-mounted or overhead sign?Overhead.

(7) Is this a freeway or non-freeway? Freeway.

(8) Review and draw upon the sign design rulesfor freeway overhead signs.



(11) Determine font, letter size, and case from SignPattern Template. The font is Series E(m), thetext is mixed upper/lower case, and the lettersize is 410/300 mm.

(12) Type out all text in Series E(m) in sign designprogram.

(13) Determine arrows, crowns, symbols to beused (type and size) from the SPT and theSign Parts Library in the MSL. There are nocrowns, and the arrows/EXIT panelcombination is taken from the SPL.


(15) Insert horizontal spacing and justificationbetween text blocks and symbols, arrows, etc.The height of the largest letter (H) is 410 mm.The word ‘Kingsmount’ is 3820 mm wide andthe word ‘Park’ is 1430 mm wide. The word‘Road’ on the second line is also 1430 mmwide. The minimum top text line length(Kingsmount Park) is 5660 mm (3820 + 410+ 1430). The minimum bottom text linelength (Road) is 1430 mm. The bottom line isto be centred under the top line, hence thecombined text block width (both lines) will be5660 mm. The minimum space between the

combined text block and the left side of theeither/or arrow is 820 mm. The width of theblock of the two arrows and the EXIT panel is3121 mm. The minimum margin spacing onthe left, between the left edge of the textblock and the left edge of the sign is 410 mmplus the border width of 50 mm = 460 mm(aluminum extrusion). The minimum marginspacing on the right, between the right edgeof the EXIT panel and the right edge of thesign is 292 mm. Note that the margin spacebetween the right edge of the EXIT panel andthe right edge of the sign is here notgoverned by the largest letter height, but bythe dimension given for these arrow blocks inthe SPL.

(16) Determine the minimum width of the sign,which is the length of the longest lineincluding text, symbols, spaces, margins, andborders. The minimum width (includingborders) is 50 + 410 + 5660 + 820 + 3121 +292 = 10353 mm. This is 33.97 feet. This fitsalmost perfectly on a 34 foot aluminumextrusion sign; a minor amount of expansion,0.03 feet or 9 mm, would be necessary. If weapply an expansion of 9 mm, the left marginspace may be increased from 50 to 59 mm.

(17) Insert vertical spacing between lines andsymbols, etc. Check the SPT. The minimumspacing between the lines of text should be0.5 to 0.75H, which is a minimum of205 mm. The spacing within the block ofarrows and EXIT panel is given in the SPL.

(18) Determine the minimum height of the sign,considering the height of all elements, withreference to Step 17. Considering the lines oftext first, the minimum vertical dimensionshould be 273 + 410 + 306 + 410 + 273 =1672 mm. The minimum vertical dimension



of the block of arrows and EXIT panel itself is1651 mm (from SPL). The SPL shows the topmargin from the top of the highest arrow tothe top edge of the sign, to be 175 mm, andthe bottom margin from the bottom of theEXIT panel to the bottom edge of the sign tobe 300 mm. Considering the block of arrowsand EXIT panel, the minimum verticaldimension should be 175 + 1651 + 300 =2126 mm. This is slightly less than the 7 feetshown on the SPT (shown as 2100 mm, butactually 2134 mm). The top margin (above thearrow block) is increased by 3 mm to 178mm and the bottom margin (below the arrowblock) is increased by 5 mm to 305 mm. Theoverall minimum vertical dimensions will be178 + 1651 + 305 = 2134 mm.

The vertical spacing of the lines of text nowneeds to be readjusted, to make up the 2134mm height. The text font size remains thesame, and the three minimum spaces of 273,306, and 273 mm are each increased by(2134-1672)/3 = 154 mm, so that thesespaces become 427, 460, and 427 mm.

(19) Add the borders to the sign design, 50 mmwide and square or rounded corners, asspecified in Table 2.14.


(21) Check whether the sign width violates anyphysical width constraints. It does not. A 34foot wide sign can be installed over a two-lane roadway with shoulders. Location dataindicated there were no space constraints.

(22) Since this is an overhead sign, check to seewhether maximum sign area and height areexceeded. Sign height is 7 feet, which is lessthan the maximum of 9 feet. Sign area is 7 x34 = 238 square feet, which is less than themaximum of 450 square feet (42 squaremetres). This is satisfactory.


Example 5

Figure 2.23 – Customized Standard SignADVANCE DESTINATION Tab (Gd-6A)

Location data: Posted speed is 80 km/h; two-lanerural road (one lane each direction); ground-mounted sign; good vertical and horizontalalignment.




(3) Required sign is Gd-6A; nominal size is1200 mm (for three lines) x variable, rangingfrom 1500 mm to 1800 mm to 2100 mm to2400 mm. Actual size needs to bedetermined through the design process.



(4) Locate Gd-6A Sign Pattern Template in MSL.


(6) Is this a ground-mounted or overhead sign?Ground-mounted.

(7) Is this a freeway or non-freeway? Non-freeway.

(8) Review and draw upon the sign design rulesfor non-freeway ground-mounted signs.



(11) Determine font, letter size, and case from SignPattern Template. The font is Series D, the textis all upper case, and the letter size is150 mm.

(12) Type out all text in Series D in sign designprogram.

(13) Determine arrows, crowns, symbols to beused (type and size) from the SPT and theSign Parts Library in MSL. There are nocrowns, the advance left arrow is A125-180-80, and the advance channelized right turnarrow is A125-80-80.


(15) Insert horizontal spacing and justificationbetween text blocks and symbols, arrows, etc.The height of the largest letter is 150 mm.The word ‘Orchards’ is 995 mm wide and thewords ‘Caledon East’, including a spacebetween the words of 150 mm, are 1432 mmwide. The space between the arrow and theadjacent text is 150 mm in each line. Eachline (text plus arrow) is to be centred

horizontally on the sign. The minimum marginspacing on the left, between the left edge ofthe sign and the arrow (top line) or first word(bottom line) is 150 mm plus the borderwidth of 25 mm = 175 mm (plywood blank).The minimum margin spacing on the right,between the right edge of the sign and theadjacent text (top line) or arrow (bottom line)is 150 mm plus the border width of 25 mm =175 mm. The width of the advance left turnarrow (A125-180-80) is 270 mm and thewidth of the advance channelized right turnarrow (A125-80-80) is 130 mm.

(16) Determine the minimum width of the sign,which is the length of the longest lineincluding text, symbols, spaces, margins, andborders. The minimum width of the line with“Caledon East” (including borders) is 25 +150 + 1432 + 150 + 130 + 150 + 25 =2062 mm. The next size up is 2100 mm. Ifthe two margin spaces are each increased by13 mm and the space between the word“East” and the arrow is increased by 12 mm,the total width will be 25 + 163 + 1432 +162 + 130 + 163 + 25 = 2100 mm. Theblock of text and arrow in the top line ofOrchards is 270 + 150 + 995 = 1415 mm,and is centred within the 2100 mm signwidth.

(17) Insert vertical spacing between lines andsymbols, etc. Check the SPT. If there were nointernal borders between lines, the minimumspacing between the lines of text should be0.5 to 0.75H, which is a minimum of 75 mm.However, this sign has internal bordersbetween lines, and hence the minimumspacing between the text and the adjacentinternal border should be 0.67H or 100 mm,including the 20 mm internal border. Theminimum spacing between the text and theadjacent edge of the sign should also be



0.67H or 100 mm, including the 25 mmouter border. The minimum clear verticalspacing between the vertical extremities ofthe arrows and the adjacent borders shouldbe equal to the width of the outer border (inthis case, 25 mm). This means that theminimum vertical spacing between thevertical extremity of the arrow and theadjacent border (including border width)should be 45 mm for internal borders and50 mm for external borders.

(18) Determine the minimum height of the sign,considering the height of all elements, withreference to Step 17. Considering the lines oftext first, the minimum vertical dimensionshould be 100 + 150 + 80 + 20 + 80 + 150+ 100 = 680 mm. The next larger standardsign size is 900 mm. Increase each of thetwo outer spaces by 50 mm each, and eachof the two inner spaces by 60 mm, so thatthe spacing becomes 150 + 150 + 140 + 20+ 140 + 150 + 150 = 900 mm. The sign istherefore 900 mm x 2100 mm, and the signblank (from the sign blank table, Table 5.1 inSection 5 or in the MSL) is B-39.

(19) Add the borders to the sign design, 25 mmwide and squared corners, as specified inTable 2.12.


(21) Check whether the sign width violates anyphysical width constraints. It does not.

(22) This is not an overhead sign, hence maximumsign area and sign height constraints do notapply.


Example 6

Figure 2.24 – Diagrammatic Sign(No Sign Number)

Location data: Posted speed is 100 km/h; ruralfreeway (QEW) (three lanes each direction);overhead sign; good vertical and horizontalalignment. Sign to depict diagrammatically a three-lane roadway splitting into two two-lane roadways,with an either/or lane.



(2) Identify class of sign: Diagrammaticdirectional guide sign, a customized standardsign.

(3) Is required sign available from another source?No.

(4) Locate Diagrammatic Sign Pattern Template(example) in MSL.

(5) Is this the right example for this sign? Yes, buteach diagrammatic sign needs to be customdesigned.

(6) Is this a ground-mounted or overhead sign?Overhead.

(7) Is this a freeway or non-freeway? Freeway.



(8) Review and draw upon the sign design rulesfor freeway overhead signs and fordiagrammatic signs.


(10) Choose arrow configuration design from SPL,if it exists. If there is no identical arrow in theSPL, either create a new one or adapt one ofthe arrow configurations in the SPL, using thesoftware drawing tools.

(11) Arrange sign elements spatially for visualclarity.

(12) Determine font, letter size, and case from SignPattern Template. The font is Series E(m), thetext is mixed upper/lower case, and the lettersize is 410/300 mm.

(13) Type out all text in Series E(m) in sign designprogram.

(14) Determine crowns to be used (type and size)from the SPT and the Sign Parts Library inMSL. From the general guidelines, design thesign using an MC-5 crown, to start with.

(15) Determine colours to be used (from SPT ifavailable, or sign class)

(16) Insert horizontal spacing and justificationbetween text blocks, crowns and arrows. Theheight of the largest letter (H) is 410 mm. Thetwo MC-5 crowns are each 1067 mm highand 1372 mm wide. The words “Bridge toU.S.A.” (longest line to the left of the arrows)are 5061 mm wide. The words “Niagara Falls”(longest line to the right of the arrows) are3937 mm wide. These dimensions include aspacing between words of H or 410 mm. Thespace between the arrow and the adjacenttext (or crown if applicable) is also at least 410

mm at the closest point, on each side of thearrow. Each line (text or crown) is to becentred horizontally on the sign, within thespace defined by the minimum spacing fromthe arrow. The minimum margin spacing onthe left, between the left edge of the sign andthe word “Bridge” is 410 mm plus the borderwidth of 50 mm = 460 mm (aluminumextrusion). The minimum margin spacing onthe right, between the right edge of the signand the word “Falls” is 410 mm plus theborder width of 50 mm = 460 mm. The textlines on either side of the arrow should notencroach closer to the arrow horizontally thanthe edge of the arrow tip. If the spacing of “H”brings the text closer than this, then the edgeof the arrow becomes the governing factor inthe horizontal spacing between text andarrow.

(17) Determine the minimum width of the sign,which is the length of the longest lineincluding text, crowns, arrows, spaces,margins, and borders. The minimum width(including borders) is 50 + 410 + 5061 +2530 (arrow width) + 3937 + 410 + 50 =12448 mm. This is 40.83 feet. The next sizeup is 42.00 feet, or 12802 mm, an increaseof 354 mm from the minimum width. Thisadditional space should be divided into fourequal parts, each 88.5 mm wide, and used tocreate additional space around text blocks. Tosimplify the numbers, a spacing of 89 mm oneither end and 88 mm between text andarrows could also be used. The widthdimensions then become 50 + (410 + 89) +5061 (+ 88) + 2530 + 3937(+88) + (410 +89) + 50 = 12802 mm. Taking the left textblock as a unit, and the right text block as aunit, each of these units should be centredwithin its somewhat increased availablespace. The centre of the left text block is then50 + 410 + 89 + (0.5) * 5061 = 3079.5 mmfrom the left edge of the sign. The centre of



the diagrammatic arrow is 50 + 410 + 89 +5061 + 88 + (0.5) * 2530 = 6963 mm fromthe left edge of the sign. Similarly, the centreof the right text block is 50 + 410 + 89 +(0.5) * 3937 = 2517.5 mm from the rightedge of the sign.

(18) Check whether the sign width violates anyphysical width constraints. It does not. The 42foot sign will fit satisfactorily over threeroadway lanes with shoulders.

(19) Insert vertical spacing between lines andsymbols, etc. Check the SPT. The minimumspacing between the lines of text should be0.5 to 0.75H, which is a minimum of210 mm. With upper/lower case text, 0.75Hor 315 mm is preferable. The minimumspacing between the lowest line of text andthe bottom edge of the sign should also be0.67H or 270 mm, including the 50 mmouter border. The minimum vertical spacingbetween the vertical extremity of the arrowand the adjacent border (including borderwidth) should be 0.25H (105 mm) at the topof the sign and 0.5H (210 mm) at the bottomof the sign. However, the standard height forall diagrammatic arrows is 8 feet (2438 mm)on a 9 foot sign, leaving only 1 foot (305mm) for the two margins and borders, whichis slightly less than the 315 mm (105 + 210).The upper margin including border widthshould therefore be 102 mm and the bottommargin including border width should be203 mm.

(20) Determine the minimum height of the sign,considering the height of all elements, withreference to Step 19. Considering the lines ofcrown and text first, the minimum verticaldimension should be 100 (i.e., twice theborder width) + 1067 + 205 + 410 + 315 +410 + 270 = 2777 mm. (9.11 feet).

Diagrammatic signs are typically designed ata height of 9 feet (the maximum) in order tohave space for well-proportioneddiagrammatic arrows.

(21) This is an overhead sign, check whethermaximum sign area and sign heightconstraints are exceeded. The sign height asdesigned is 9.11 feet and exceeds thepermissible 9 feet by 34 mm. In this instance,interline spacing can be reduced toward theminimum by making the spacing 281 mmrather than 315 mm. This results in a signheight of 2843 mm or 9 feet. This height willalso accommodate the diagrammatic arrowas outlined in Step 20.

(22) Add the borders to the sign design, 50 mmwide and square or rounded corners, asspecified in Table 2.14.


(24) Since this is an overhead sign, check to seewhether maximum sign area and height areexceeded. Sign height is 9 feet, which equalsthe maximum of 9 feet. Sign area is 9 x 44 =396 square feet, which is less than themaximum of 450 square feet (42 squaremetres). This is satisfactory.




Figure 3.1 – Concept of RetroreflectivityUsing Glass Bead Technology

3. Sign Materials

Most signs are assembled by applying sheeting to arigid sign blank. In some cases, signs are screenedon reflective sheeting. This section describes thematerials from which signs are fabricated andassembled, the specifications commonly used inOntario to control the production of these materials,and procedures for testing material performance.Section 4 deals with the fabrication of signs,including substrate preparation. Book 3 (SignSupport and Installation), yet to be developed,covers sign posts, structures and hardware.

Sign material technology is continually evolving.Road authorities are generally encouraged to keepabreast of new available materials, which may beused, provided that they have been sufficientlytested to prove they meet or exceed theperformance requirements of materials currentlyin use.

3.1 Sign Face Materials

Sign face materials include:

• adhesive sheeting;• screen printing ink and coatings; and• computer cuttable transparent or opaque

overlay films.

These materials may be used in combination withone another. However, not all inks and sheetings arecompatible with each other. Manufacturers’specifications and recommendations should befollowed to ensure good sign performance andenforceable warranties.

3.1.1 Types of Sign Sheeting

Most signs on Ontario’s roadways are faced withretroreflective sheeting. As described in Section 2.9(Reflectorization and Illumination), retroreflectivesheeting refracts light from headlights so that mostof it is reflected back to the driver and less isdiffused to the periphery of the sign (see Figure3.1). The coefficient of retroreflectivity (i.e., theR-value) was also defined in Section 2.9 as theproportion of light reflected back to the driver. Manysigns use non-reflective black material (acrylic orvinyl) or black ink for all or part of the signmessage. While non-reflective coloured sheetingsare available, they are rarely used, because a signneeds to be retroreflective to ensure that its shape,colour, and message are retained at night.

Various types of retroreflective sheeting are availabletoday. Table 3.1 defines the types of sheeting interms of name, structure, typical applications, anapproximate brightness index and an approximatecost index. The brightness and cost indices arebased on the Type I values, which are assigned anindex value of 1. In general, the higher the typenumber (except within Types VII, VIII and IX), thegreater the amount of light reflected back to thedriver’s eyes. Guaranteed and reported service life,which also vary according to sheeting type, arediscussed in Section 3.2.1 (Durability and ServiceLife) below.



1 Includes data from: ASTM D 4956-01a; FP-96 (Standard Specifications for Construction of Roads and Bridges on Federal Highway Projects,FHWA, 1996); http://members.aol.com/rcmoeur/sgnsheet.html.

2 Based on ASTM D 4956-01a for white sheeting at entrance angle = -4 degrees and observation angle = 0.2 degrees.3 Approximate values.

Table 3.1 – Types of Retroreflective Sheeting1

ASTMType

I

II

III

IV

V

VI

VII

VIII

IX

Name

EngineeringGrade

Super-EngineeringGrade

HighIntensityGrade

HighIntensityPrismatic

Super-highIntensity

ElastomericHighIntensity

Super-highIntensity(long-mediumdistance)

Super-highIntensity(long-mediumdistance)

Very-highIntensity(shortdistance)

Structure

• Enclosed lens glass-beadmaterial

• Very small glass beadsenclosed in a pigmentedsubstrate

• Enclosed lens glass-beadmaterial

• Encapsulated glass-beadmaterial

• Outer transparent pigmentedlayer and inner reflective layerfaced with glass beadsconnected by honeycomblattice

• Non-metallized micro-prismaticmaterial

• Multi-layer sheeting• Reflective layer made of

microscopic cube-cornerreflectors

• Metallized micro-prismaticmaterial

• Vinyl microprismatic material• Sheeting without adhesive

• Non-metallized high reflectivitymicro-prismatic material

• Distinguished by diamond-shaped lattice separatingsheeting layers



• Similar to Type VII, with finegrain microprisms

Applications

• Permanent highwaysigning, work zonedevices, delineators



• Permanent highwaysigning, constructionzone devices,delineators

• Delineators and raisedpavement markers

• Temporary roll-upsigns, warning signs,traffic cone collars,post bands, clothing




Bright-ness

Index2

1

2

4

4

10

3.5

11

10

5.5

CostIndex3

1

<2

2

2

5.5

6

5

5

5

Comments

• Designed for narrow angleviewing (i.e., long distance)

• Brightness index decreases to<3 for 30 degree entranceangle

• Highest retroreflectivity at longand medium road distances

• Brightness index increases to19 for 30 degree entranceangle

• Highest retroreflectivity at longand medium road distances

• Blue colour brighter than forType VII

• Spec for brown (but not forother Type V or higher)

• Designed for widerobservation angles whendriver eye is close to sign

• Brightness index increases to8 for 0.5 degree observationangle



In the Ontario Traffic Manual, one of four grades ofretroreflective sheeting (or equivalent) is typicallyspecified for signs: Type I (engineering grade), TypeIII or IV (high intensity), or high reflectivity micro-prismatic sheeting. The high reflectivity micro-prismatic sheeting specified in the OTM isfluorescent retroreflective sheeting. Material ofType VII, Type VIII or Type IX meets this description;specifications and manufacturers’recommendations should be checked as to whichtype is best for a given application. In most cases,sheeting with higher retroreflectivity may be usedinstead of the minimum sign sheeting specified.

The OTM mandates the use of high intensitysheeting (Type III minimum) or high reflectivitymicro-prismatic sheeting (Type VII or higher) forseveral signs which are critical from a safetystandpoint, that is, failure to see or heed thesesigns at night could have serious consequences.See Book 5 (Regulatory Signs), Book 6 (WarningSigns) and Book 7 (Temporary Conditions). InOntario, high intensity sheeting is also typically usedfor the legends of overhead freeway guide signs,and some jurisdictions use high intensity sheetingfor both the legends and backgrounds of thesetypes of signs. However, it may make sense to usehigh intensity sheeting or high reflectivity micro-prismatic sheeting for other applications also, fornew signs installed and as part of a regular signreplacement program. In addition to the obviousbenefit of improving legibility, high intensitysheeting or high reflectivity micro-prismaticsheeting is also often more cost effective over thelife of the sign. See Section 3.2.3 (Benefit/CostConsiderations).

In addition to the types of sheeting describedabove, fluorescent sheeting is also available.Fluorescence is the emission of light immediatelyupon exposure to radiation. Fluorescent substancesappear to glow vividly when they are irradiated, byultra-violet radiation, for example. This effect is dueto the absorption of short wavelengths of radiation

and their re-emission at longer visible wavelengths.Therefore, fluorescent-coloured sheeting appearsbrighter and more conspicuous than other types ofsheeting by day, and particularly at twilight andunder overcast conditions. Fluorescent sheeting hasminimal effect on the nighttime performance ofsigns, when compared to non-fluorescentretroreflective sheeting. Because of its uniqueproperties, fluorescent sheeting may be consideredfor applications where there is a problem withdaytime conspicuity, for example at high conflict orhigh collision locations. At least one manufacturersupplies high reflectivity micro-prismatic sheetingwhich is also fluorescent and has a practicable lifecycle. Other manufacturers supply fluorescentsheeting, but without the high reflectivity micro-prismatic characteristics.

3.1.2 Sheeting Standardsand Specifications

R-values associated with several types ofretroreflective sheeting are detailed in the ASTMSpecification D 4956-01a (or its subsequentrevisions). (Note: these R-values are referred to inthe ASTM specification and in some otherpublications as RA). Type I to Type IX (inclusive)sheetings are covered in the ASTM specification.Fluorescent sheeting is not defined in the 2001version of the specification. In Canada, the CGSBSpecification 62-GP-11 (or its subsequent revisions)also specifies retroreflective sheeting. The CGSBspecification has not been revised since 1987 anddoes not cover sign sheetings of Type IV or higher.Note also that the CGSB designations are thereverse of the ASTM designations. That is, ASTMType I is CGSB Level 2; ASTM Type III is CGSBLevel 1.

In the specifications, R-values are provided fordifferent entrance angles and observation angles.The entrance angle is the angle between theheadlight beam and the perpendicular to the sign



face (see Figure 3.2). The observation angle is theangle formed by light travelling from the headlightand reflected off the sign back to the driver’s eye(see Figure 3.3). Larger entrance and observationangles result in lower R-values.

The entrance angle is affected by:

• the horizontal sign offset;• sign mounting height (vertical offset);• the distance between the vehicle and the sign;• the travel lane of the vehicle;

• the curvature of the roadway;• tilt angle of the sign about its vertical axis

(horizontal angling of side-mounted signs); and• tilt angle of the sign about its horizontal axis

(vertical angling of overhead signs).

The observation angle is affected by:

• the distance between the vehicle and the sign;• sign mounting height (vertical offset); and• the distance between headlight height and driver

eye height.

Figure 3.2 – Entrance Angle

Figure 3.3 – Observation Angle



One difference between the ASTM standard andthe CGSB standard is that the CGSB standard setsout a performance level requirement at 50 degreesentrance angle, while the widest entrance angle forwhich the ASTM standard specifies a performancelevel is 30 degrees. If signs are to be installedwhere entrance angles are greater than 30degrees (e.g., if the sign has a very large horizontalmounting offset, or the sign is tilted well away fromthe perpendicular to the road), the CGSBspecification may be used.

The R-values vary according to colour, with darkercolours having generally lower R-values. Forexample, minimum ASTM R-values for new Type I,Type III, Type VII, and Type IX sheeting of variouscolours, measured at an observation angle of 0.2degrees and an entrance angle of -4 degrees, areshown in Table 3.2. These R-values should beconsidered as guidelines only. Typically, newsheeting has much higher values, by on the orderof 30%, than the minimum ASTM values indicatedin the table.

Testing Procedures

ASTM D-4956-01a prescribes performancerequirements and corresponding testing proceduresfor a number of sign sheeting properties, asindicated below. There are supplementary

performance requirements in addition to themandatory ones. The supplementary requirementsapply only when specified by the purchaser in thecontract or order. Some of the tests for the varioussheeting properties reference other ASTMStandards, primarily specifications, test methodsand practices.

Coefficient of RetroreflectionFor each sheeting type, tables indicate theminimum coefficient of retroreflection required fornew sheeting at various:

• Observation angles, including 0.1 degrees, 0.2degrees, 0.5 degrees and/or 1.0 degrees,depending on the sheeting type. Values for 0.1degree observation angles are supplementaryrequirements that apply only when specified bythe purchaser in the contract or order;

• Entrance angles, including -4 degrees and +30degrees; and

• Colours, including white, yellow, orange, green,red, blue and brown. (Specifications for brownsheeting are not included for Types V, VI, VIIand IX.)

Daytime ColourDaytime colour specification limits are definedusing four pairs of chromaticity coordinates todetermine the acceptable colour in terms of the CIE1931 Standard Colorimetric System.

Minimum and maximum daytime luminance factorsfor different colours of sheeting are provided inthree separate tables:

• For non-prismatic material (Types I, II, III and VI);

• For non-metallized microprismatic material (TypesIV, VII, VIII and IX); and

• For metallized microprismatic material (Type V).

Colour Type I Type III Type VII Type IX

White 70 250 750 380

Yellow 50 170 560 285

Orange 25 100 280 145

Green 9 45 75 38

Red 14 45 150 76

Blue 4 20 34 17

Brown 1 12 – –

* Observation Angle = 0.2 DegreesEntrance Angle = -4 Degrees

Table 3.2 – ASTM R-Values*(candelas/lux-m2)



Accelerated OutdoorWeathering RequirementsSheeting must be weather resistant and show noappreciable cracking, scaling, pitting, blistering,edge lifting, or curling, and remain within specifiedlimits for shrinkage and expansion, when testedaccording to the procedure described in thespecification.

The minimum coefficient of retroreflectivity requiredto be retained after the weathering tests isindicated for each sheeting type in terms ofpercentage of the minimum required new R. Theoutdoor weathering test time varies by sheetingtype and ranges from 6 months to 36 months.Regardless of sign sheeting type, when the coloursorange, yellow or white are specified forconstruction work zone applications, the outdoorweathering test time requirement is 12 months.

ColourfastnessAfter it has been tested for outdoor weatheringusing the specified tests, retroreflective sheetingmust retain its specified daytime colour properties.

ShrinkageThe absolute minimum shrinkage allowances areprovided, effective after testing for 10 minutes andfor 24 hours, according to the specified tests.

FlexibilitySheeting must be sufficiently flexible to show nocracking when tested according to the proceduredescribed in the specification.

Liner RemovalIf a liner is provided with the sheeting, it must beeasily removable after being subjected to theaccelerated storage test described in thespecification. The liner must be easily removablewithout soaking in water or other solution, andmust not break, tear or remove adhesive from thesheeting upon removal.

AdhesionThe specification indicates the bond strength of theadhesive backing of the sheeting, in terms ofminimum weight supported for 5 minutes, withoutthe bond peeling for more than a specifiedmaximum distance, when tested according to theprocedure described in the specification. Theminimum weight that must be supported varies byclass of adhesive.

Impact ResistanceSheeting must show no cracking or delaminationoutside of the actual area of impact whensubjected to the impact test described in thespecification.

Specular GlossThe specification indicates the minimum requiredspecular gloss value, after testing as indicated inthe specification.

Fungus Resistance (Supplementary Requirement)Performance requirements and tests for fungusgrowth and fungus damage are provided for use inareas where fungus growth on retroreflectivesheeting may be a problem.

Reboundable Sheeting Requirements(Supplementary Requirement)Sheeting must show no cracking or delaminationoutside the actual area of impact when subjectedto the supplementary impact test described in thespecification.

Artificial Accelerated Weathering(Supplementary Requirement)The supplementary test described in thespecification may be used for provisionalqualification of sheeting before the results fromoutdoor weathering are available. When theybecome available, the results from outdoorweathering take precedence over the results fromlaboratory-accelerated weathering tests.



In addition to performance requirements and testprocedures, ASTM D 4956-01a providesinformation on general requirements (e.g.,tolerances for sheets and rolls), packaging andpackage marking, and ordering information apurchaser should provide when using thespecification to procure retroreflective sheeting. Thespecification also defines four classes of adhesivebacking. Sheeting adhesives are discussed inSection 4 (Sign Fabrication).

3.1.3 Screen Printing Ink and Coatings

For frequently used sign patterns, e.g., STOP signs,it is feasible to screen coloured ink onto reflectivesheeting. Users should follow manufacturers’specifications and recommendations for bothsheeting materials and inks to ensure goodperformance and compatibility between the twotypes of material and to ensure enforceablewarranties.

Positive screening is used for signs with legendsthat are darker than their backgrounds, e.g., mostwarning signs. The legends of these signs areapplied directly onto the coloured sign face withopaque black ink. Negative screening is used forsigns with legends that are lighter than theirbackgrounds, e.g., STOP and YIELD signs. For thesetypes of signs, transparent ink in the backgroundcolour is applied over the entire sign face, with theexception of the legend. For example, in Ontario,STOP and YIELD signs are typically screened in redtransparent ink over high intensity white sheeting,allowing the retroreflective sheeting to act throughthe ink. Where transparent inks are used inscreening, the ink should have the sameguaranteed life cycle as the retroreflective sheeting(see Section 3.2.1 for information on guaranteedlife cycles of retroreflective sheeting).

Clear-coatings are often applied to screened signsfor protection. Advances have been made in thedevelopment of coatings which better protect signssuch as STOP signs from degradation due to ultra-violet radiation. Graffiti-resistant inks and coatingsare also available. These coatings are solventresistant and enable graffiti to be easily wiped offthe sign face. They may also feature non-sticksurfaces to facilitate sticker removal.

As described in Section 4 (Sign Fabrication), direct-applied retroreflective sheeting copy is also oftenused in sign manufacture.

3.2 Sign Sheeting Performance

Sign sheeting performance is critical to the overallperformance of a sign, as the sheeting typicallydegrades before the substrate and the other signcomponents. Knowledge of how sheeting degradesand of realistic expected life cycles for sign sheetingmaterials can assist a practitioner in making cost-effective decisions on which sheeting to use fordifferent applications.

3.2.1 Durability and Service Life

The durability of a sign sheeting depends on howlong and how well it is able to withstand exposureto natural and man-made elements, primarily ultra-violet (UV) radiation from sunlight, but also, wind,rain, ice, pollution and extreme temperatures. Thetype of sheeting failure is related to the structure ofthe sheeting. Single layer sheeting, such as Type Ior Type II, usually fails by gradually losingretroreflective intensity. Exposure to ultra-violet raysthrough sunlight, as well as heat and pollutioncauses the pigmented material to fade. This type ofUV fading is also particularly damaging totransparent inks, such as those used to screenSTOP and YIELD signs. Signs with a southernexposure degrade the fastest. Multi-layer sheeting,



such as Type III and Type IV, fails structurally. Theouter coloured layer delaminates and falls off,exposing the silver reflective layer beneath to theelements, and decreasing the contrast required forlegibility.

Different types of sign sheeting have differentlengths of service life (see Table 3.3). For severalreasons, it is difficult to directly compare the servicelife of different sheeting types. Manufacturersguarantee a type of sheeting for a given number ofyears, by specifying the percentage of the R-valuesrequired by the ASTM specifications for newsheeting that will still be in place at the end of theguarantee period. The percentages, however, varyfrom 50% to 80% by sheeting type. The absolute R-value requirements for different sheeting types arealso different.

These differences result in a wide variation amongthe absolute R-values required at the end of theguarantee period. With higher sheeting types, thepercentage of the new R-value that is guaranteed tothe end of the life cycle is generally higher. Forexample, with Type I sheeting, 50% of its newR-value is guaranteed at the end of 7 years (R at

end of life cycle = 35 for white sheeting atobservation angle = 0.2 degrees and entranceangle = -4 degrees), while with Type III sheeting,80% of its new R-value is guaranteed at the end of10 years (R at end of life cycle = 200 for the sameangles). With Type VII sheeting, 70% of its newR-value is guaranteed at the end of 10 years (R atend of life cycle = 525 for the same angles). Thereis a fifteen-fold difference between the Type VII andthe Type I guaranteed end-of-life R-values in thisexample.

As Table 3.3 shows, the reported service life ofretroreflective sheeting, observed through actualexperience, may be somewhat longer than coveredby the guarantee. A further consideration is thatsign manufacturers produce sheeting that may farexceed the ASTM specification for a given type ofsheeting, but market it as meeting that specificationbecause test procedures for the lower type arealready in place. Setting up new or additionaltesting procedures may not be cost-effective. Also,some products fall between the standards for twoconsecutive types of sheeting and therefore arebrighter than the next lowest specification available.

Table 3.3 – Sign Sheeting Service Life

Guaranteed Reported % of New R Absolute R*[years] [years] [candelas/lux-m2]

I 7 7 50% 35

II 10 15 50% 70

III 10 17-20 80% 200

IV 10 unknown 80% 200

VII 10 13 70% 525

VIII 10 unknown 70% 490

IX 10 10+ 70% 266

Type Service Life Guaranteed End-of-Life R-Value

* White SheetingObservation Angle = 0.2 DegreesEntrance Angle = -4 Degrees



3.2.2 Benefit/Cost Considerations

If higher intensity sheeting has longer service life, itmay prove to be economically advantageous to use,even if it is initially more expensive. Using higherintensity sheeting generally increases nighttimelegibility and conspicuity. (In some situations, e.g.,Type IV sheeting, the legibility and conspicuitybenefits only apply for specific observation andentrance angles.)

In limited situations, increasing sign brightness canbe traded off against increasing sign size. Whenthere is a choice of increasing font size orincreasing reflectivity to achieve nighttime legibility,increasing sign size is preferred since it improvesdaytime and nighttime visibility. Where increasingfont size is not feasible (e.g., due to placementconstraints, sign size structural limits, costconsiderations, etc.), material reflectivity can beincreased until an equivalent legibility is obtained.

The analyses of benefit/cost assume that a higherreflectivity value over the life of the sign isnecessary and valuable. This may not always be thecase. For example, although in a crowded urbanenvironment increased sign reflectivity may increaseconspicuity, with real benefit, in an open rural areawith little visual competition, engineering gradesheeting may provide sufficient conspicuity.

To compare life cycle costs of signs made of varioussheeting types, annual costs provide a truecomparison. While the Equivalent Uniform AnnualCost (EUAC), amortized using a discount rate over afixed number of years provides more accuratevalues, a useful comparison can be made by simplycalculating average annual cost as follows:

Since the above approximation of EUAC does notincorporate a discount rate for amortization, it isslightly biased in favour of the sign with the longerservice life (i.e., the cost savings for a sign with alonger service life are slightly greater than if a non-zero discount rate were applied).

In the above equation, total cost is taken to be alllife cycle costs for materials and labour associatedwith a new sign installation or an overlay of anextruded sign. (Extruded signs can be overlayedrather than replaced in entirety when the sheetingdegrades.) Total cost includes the following items:

• Materials – Sheeting, substrates/blanks,supports, bracing, hardware;

• Labour – Fabrication, installation, dismantling,inspection, maintenance;

• Salvage Value (Negative Cost) – Aluminum,other recyclable materials.

The values used for service life in the equationshould make some allowance for the reported lifeof the sign, to render a realistic estimate. Averagingthe guaranteed sheeting service life and thereported service life would be an acceptableapproach. Actual experience with sheeting servicelife within the jurisdiction should be reflected in thevalues used.

Once the average annual cost is obtained for thesigns constructed with the sheeting types beingcompared, cost savings can be calculated by thefollowing formula:

where: HAAC = Higher Average Annual CostLAAC = Lower Average Annual Cost

Total CostService Life

Average Annual Cost =



A benefit/cost analysis of sign sheeting should takeinto account the following practical considerations:

• The analysis does not apply to temporarysheeting, which may be used for short periodsonly, or reinstalled several times.

• If signs are destroyed before reaching the end oftheir service life, e.g., through vandalism, knockeddown by trucks, damaged by weather, etc., thesavings resulting from a longer sheeting servicelife cannot be fully realized. Assuming that arandom distribution of old and new signs aredestroyed each year, the annual cost savingsresulting from using a sign with a longer servicelife is decreased by about 1% to 3%, perpercentage of total signs annually destroyed. Forexample, if 2% of all signs in a jurisdiction wereannually destroyed, the annual cost savingsassociated with a sign with a longer life would bedecreased by 2% to 6%.

• Some high performance sheeting is more fragileand requires more care in fabrication, handlingand storage. For example, specialized tools (hotknife) are required for cutting Type VII sheeting.Some agencies may not be equipped to providethis level of control.

• It may not be efficient to inventory and fabricatesigns from many different sheeting types tooptimally accommodate various signingscenarios. A more practical approach would beto select a few sheeting types to handle overalljurisdictional requirements.

3.3 Sign Substrates

Sign substrates are the materials from which signblanks are fabricated, and to which retroreflectivesheeting is then applied. This section describescommonly used substrate materials andspecifications controlling their production.

Depending on the material, substrates need to belevelled, smoothed, cut to standard blank size,stamped to form radius corners and holes for signmounting, deburred if screen-printed, weather-proofed and/or surface-treated to improveadhesion. These processes are discussed inSection 4.1 (Substrate Preparation).

3.3.1 Substrate Materials

The materials described below are most commonlyused as sign substrates. The advantages anddisadvantages of each type of substrate should beconsidered for the specific signing application.

Aluminum

Aluminum is the most frequently used substrate forsmall signs. In Ontario, aluminum is typically usedfor signs 600 mm x 600 mm or smaller. Aluminumis lightweight, has a long life and will not rust. It isusually more expensive than steel or plywood,although depending on price fluctuations,aluminum may at times be more cost effective thangalvanized steel, especially given the fact thataluminum can be recycled. Being lightweight,aluminum is susceptible to bending from strongwinds or vandalism, and may require cross-bracing;hence it is more typically used for the smaller signs.

Steel

Steel substrates can be coated in different ways,including the following:

• Galvanized Steel – Zinc-coated;

• Galvannealed Steel – Zinc-iron alloy-coated by ahot-dip process;

• Galvalume Steel – 55% aluminum-zinc alloy-coated by a hot-dip process.



Steel substrate coating requirements are describedin the specifications for steel signs (see Section3.3.2). The coatings are applied to protect the steelfrom rust, therefore the substrates are susceptible torusting if their coating becomes damaged. Steel isheavier and usually more rigid than aluminum. InOntario, galvanized steel is typically used for signsthat are larger than 600 mm x 600 mm, butsmaller than side-mounted guide signs andoverhead guide signs.

Plywood

Plywood is a medium strength substrate whichusually does not require cross-bracing. It is the leastexpensive of the commonly used substrates. It isvery porous and susceptible to weathering andcracking if not sealed. Plywood must have its edgesfilled, and edges, back and front sealed. Somesheeting manufacturers specify that both faces ofthe medium density overlay plywood (MDOP)substrate must be faceprimed and topcoated with acompatible paint. Primer and finish materialsproduced by the same manufacturer andformulated as companion products should be usedto ensure good adhesion. Conventional high qualityexterior paints formulated for wood should be used.When damaged, however, plywood is easy to repair.Plywood is typically used for temporaryreplacement signs (e.g., while a damagedpermanent sign is being repaired or replaced) andfor temporary conditions signing. Other typical usesfor plywood in Ontario include many freewaywarning signs, and, in general, signs larger than900 x 900 mm and smaller than 1200 x 2400mm. In some cases, plywood is used for signs aslarge as 2400 x 2400 mm.

Non-compliance with manufacturers’recommendations and guidelines may result inpremature failure.

Extruded Aluminum

Extruded aluminum signs are different from the flataluminum signs described above in that they arecomposed of panels with their sides bent backwardinto U-shaped extrusions. Panels can then befastened together along the length of theirextrusions to create a large sign surface.Consequently, extruded aluminum panels are mostoften used for large side-mounted guide signs andoverhead guide signs. The panels are available inseveral widths, usually 150 mm (6") and 300 mm(12"), and profiles and typically incorporate clips forfastening the panel assembly to sign posts.

Extruded aluminum panels are fastened together byeither bolting through holes in the extrusions, orsnapping using pre-fabricated snap-together panels.

Extruded aluminum panels provide a more rigidsign surface without the requirement for bracing. Itis easier to repair than sheet aluminum. A sign faceon an extruded aluminum sign can easily bereplaced using an aluminum overlay, which is a thinsheet (typically 1 mm (0.040") thick) of aluminumriveted to an existing sign or sign blank. Withaluminum overlays, the entire sign does not need tobe replaced when the sign sheeting degrades.

Combinations of flat sheet aluminum andreinforcing extrusions are sometimes also used forlarge guide signs. For example, extruded flangescan be spot-welded to sheet aluminum to formU-shaped panels, which are then fastened togetherlike extruded aluminum panels. This type ofsubstrate, known as Extrusheet, offers theadvantages of fewer panels, a larger seamless signface and the strength of conventional extrudedaluminum panels. Increment panels are anothertype of reinforced flat sheet aluminum sign. Thesesigns are constructed from vertical aluminumpanels connected with splice plates and reinforcedwith additional extruded aluminum. Increment signsare labour-intensive and are the most expensive ofthe extruded aluminum signs.



Other Substrate Materials

Other newer substrate materials include fibreglass,plastic and combined fibreglass-plastic. Thedurability of these materials has not yet been fullytested, however the experiences of somejurisdictions with field applications have shownfibreglass and plastics to be a feasible alternative toaluminum as a substrate for flat sheet signs in someapplications. Fibreglass/plastic substrates arelightweight and inexpensive. Another advantage isthat the substrate material itself can be coloured,eliminating the need to paint the back of the sign.The primary disadvantage of these types ofmaterials is their fragility. They are susceptible tofracture from high winds and impacts and mayrequire cross-bracing, although newer versions ofthe substrate are being designed to withstandhigher impacts. Some types also become brittle inextreme cold temperatures, an importantconsideration given Ontario’s climate conditions.Fibreglass/plastic requires more care in handlingthan aluminum. Other drawbacks are that sheetingdoes not adhere well to these substrates and thatplastic is subject to premature warping. Due toplasticizer migration, adhesion problems may notbe immediately apparent.

New technologies for substrates continue to bedeveloped. For example, recycled materials, such asrecycled plastic and rubber, have been developedas sign substrate materials, but have not yet beenthoroughly tested. The use of emerging substratetechnologies is encouraged, provided that they aresufficiently tested prior to adoption and that theyare able to meet the standards required ofconventional signing materials, such as rigidity,service life, durability, strength, ability to adhere tosheeting and compatibility with existing signsupport hardware. Standards and specifications forsubstrates (see Section 3.3.2) detail therequirements currently in place for conventionalsubstrates.

3.3.2 Standards and Specifications

In Ontario, the Ontario Provincial StandardSpecifications (OPSSs) are the primaryspecifications for sign substrate materials. OPSS2001 (June 1995 or subsequent revisions) dealswith material specifications for metal substrates,and OPSS 2002 (December 1990 or subsequentrevisions) deals with material specifications forplywood substrates. The content of thesespecifications is described below.

The OPSS specifications make reference to U.S.specifications or standards, and there exist otherU.S. specifications/standards for substrate materialsthat are not mentioned in the OPSS specifications.Table 3.4 lists the standards/specifications thatapply to sign substrates in Ontario, and other U.S.standards/specifications.

The OPSS specification for metal substratesprovides information on materials and thicknessesfor aluminum and steel sign blanks, and allowablesize tolerances. In addition, information is providedon: production, including substrate preparation (seeSection 4 (Sign Fabrication)) and packaging anddelivery; quality assurance; and owner purchase ofmaterial by purchase order.

Regarding materials for aluminum sign blanks,OPSS 2001 refers to ASTM B 209M (alloy6061-T6) for signs larger than 450 mm x 450 mm.This ASTM specification covers the production ofaluminum and allows flat sheet, coiled sheet, andplate, in various alloys, tempers and finishes. Signs450 mm x 450 mm or smaller must be fabricatedfrom utility sheet or coil.

OPSS 2001 specifies that steel sign blanks can befabricated from galvanized, galvalume or zinc-coated steel made from sheets or coils. Forgalvanized (zinc-coated) and galvannealed (zinc-ironalloy-coated) steel, OPSS 2001 refers to ASTM A653/A 653M (regular type coating designation



* OPSS 2002 (Dec. 1990) Material Specification for Standard 120 cm x 240 cm Overlaid Plywood Sign Blanks.

** The 2.0 mm (0.081 inch) thickness is recommended for superior performance of smaller aluminum signs, in accordancewith ASTM B 209M (alloy 5052 H-38), although some road authorities use utility grade aluminum (1.6 mm (0.064 inch)thickness, in accordance with ASTM B 209M (alloy 5052 H-52) for such signs.

Table 3.5 – OPSS-Specified Substrate Thickness*

Material Condition Thickness [mm]

Aluminum** Temporary panels 2.0

Permanent panels 750 mm x 750 mm or smaller 2.0

Permanent panels larger than 750 mm x 750 mm 3.0

Steel Coated steel 1.6

Plywood (Overlaid) Temporary conditions signs 1200 mm x 1200 mm or smaller 11.0

Permanent STOP signs 11.0

Temporary conditions signs 12.5

Permanent signs 19.0

Substrate Ontario Referenced in Ontario Other U.S.Material Standards/ Standards/Specifications Standards/SpecificationsSpecifications Specifications

Aluminum OPSS 2001 ASTM B 209M (alloy 6061-T6) FHWA FP-96

ASTM B 209M (alloy 5052-H38 and alloy 5052-H52)

ASTM B 221M (alloy 60 63-T6)

ASTM B 449

Steel OPSS 2001 ASTM A 653/A653 M FHWA FP-96(regular type coating designation Z275) ASTM A 525M

ASTM A 792/A 792 M(coating designation AZ180)

Plywood OPSS 2002 FHWA FP-96NIST PS 1-83

Plastic FHWA FP-96

Fibreglass FHWA FP-96Reinforced Plastic ASTM D 638M

ASTM D 790MASTM D 695MASTM D 732ASTM D 3841ASTM D 696ASTM D 635

Table 3.4 – Standards and Specifications for Sign Substrate Materials*

* OPSS 2001 (June 1995) Material Specification for Metal Sign Blanks.



Z275). This ASTM specification covers products in anumber of designations, types, grades and classes,pertaining to chemical composition and typicalmechanical properties of the steel sheet, which aredesigned to be compatible with differentapplication requirements. For galvalume steel, OPSSrefers to ASTM A 792/A 792M (coatingdesignation AZ180). This ASTM specificationcovers the production of 55% aluminum-zinc alloy-coated steel sheet in coils and cut lengths, in anumber of designations, types and grades whichare designed to be compatible with differingapplication requirements.

Metal substrate thicknesses specified in OPSS2001 are shown in Table 3.5, along with plywoodsubstrate thicknesses specified in OPSS 2002. Thefollowing size tolerances are specified for metalsubstrates:

• Blanks shall not deviate more than 3 mm fromthe specified size in any dimension exceptthickness;

• Blanks shall not deviate more than 0.1 mm fromthe specified thickness.

OPSS 2002 incorporates CSA and US standards.The specification covers substrate materials,overlays, production including substrate preparation(see Section 4 (Sign Fabrication)) and authoritypurchase of material by purchase order. Accordingto OPSS 2002, medium density 60/60 overlaid all-fir filled plywood must be used. The overlay mustbe Medium Density Crown Forest #360 orWeldwood #448. Specified thicknesses forplywood substrate are shown in Table 3.5.

4. Sign Fabrication

This section describes sign fabrication techniquesfor a variety of sign substrate and sheetingmaterials. Nothing in this section is intended tosupersede specific recommendations fromsuppliers, who often provide technical support inthe form of technical bulletins, training, visits, andinstruction manuals. Becoming well acquaintedwith a supplier’s recommendations, techniques andprecautions, and following them, will help ensure abetter product and eliminate waste.

Procedures for sign fabrication are illustrated inFlowchart B which consists of Flowcharts B.1through B.9 (see Section 4.6). Flowchart B.1 is anoverview flowchart.

Sign fabrication requires the use of variouschemicals, paints, inks and solvents that areregulated through the Workplace HazardousMaterials Information System (WHMIS). Eachspecific product identified under WHMIS must havea current Material Safety Data Sheet (MSDS)which describes the composition of the product. Italso gives details on the safe handling and storageof the product as well as personal protective safetyequipment that is required when using the product,and other protective devices such as fume hoodsand breathing apparatus. Handling, storage and useof each specific product must conform to theseregulations. All safety precautions must be followed,including those recommended by manufacturers forthe operation of sheeting applicators or otherequipment.

This section addresses:

• Substrate preparation, testing and storage;• Background sheeting application;• Sign assembly (extruded aluminum panels);• Legend preparation and application; and• Storage of signs.



4.1 Substrate Preparation,Testing and Storage

Metal blanks (aluminum or steel) are typically usedfor signs up to 900 mm x 900 mm in size.Plywood is typically used for signs larger than900 mm x 900 mm, up to 1200 mm x 2400 mm,and is sometimes used for signs up to 2400 mm x2400 mm. Above these sizes, extruded aluminumpanels, bolted or snapped together, are used forsign fabrication.

Plywood is also often used for signs (any size)which are temporary in nature, such as TemporaryConditions signs, and interim signing asreplacement of an existing or damaged sign or signstructure.

4.1.1 Aluminum

Procedures for metal sign blank preparation areillustrated in Flowchart B.2.

Treated aluminum blanks have been degreased,etched and have a coating applied, so they areready to accept various types of retroreflectivesheeting or vinyl sheeting immediately or at a futuredate.

Untreated aluminum blanks require preparationbefore they are ready to accept any sheeting.

If the blanks have been treated according to currentOPSS 2001, prior to acquisition from the supplier,very little preparation is required other than wipingthe surface with a tack cloth to remove dust justprior to applying the background sheeting.

When using untreated blanks, etching anddegreasing are required. This procedure should beperformed after sign blank radii and holes havebeen punched. Specifically designed dip tanks areavailable for each process using commercially

available solutions, such as chromic acid orchromium sulphate conversion coatings. Blanksshould be rinsed thoroughly using high-pressurespray with cold water and left to dry. The sheetingshould be applied immediately.

Small production volumes of untreated blanks mayalso be prepared by scrubbing the surface using anabrasive cleaner and a scouring pad, then rinsingclean with cold water, and drying immediately. Inthis case the sheeting should also be appliedimmediately.

Solvent wiping of treated blanks should only benecessary if blanks become contaminated. (i.e.,greasy fingers or other contaminates).

4.1.2 Steel

Procedures for metal sign blank preparation areillustrated in Flowchart B.2.

Treated steel blanks are fabricated from galvanizedor galvalume steel and have been degreased andcoated according to the coating designation asstated in OPSS 2001. They are then ready to acceptvarious types of retroreflective sheeting or vinylsheeting immediately or at a future date.

Untreated galvanized steel blanks may be coveredwith a thin layer of oil that must be removed beforesheeting can be applied.

If the blanks have been treated according to currentOPSS 2001, prior to acquisition from the supplier,very little preparation is required other than wipingthe surface with a tack cloth to remove dust justprior to applying the background sheeting.

When using untreated blanks, etching anddegreasing are required. This procedure should beperformed after sign blank radii and holes havebeen punched. Specifically designed dip tanks are



available for each process using commerciallyavailable solutions, such as chromic acid orchromium sulphate conversion coatings. Blanksshould be rinsed thoroughly using high-pressurespray with cold water and left to dry. The sheetingshould be applied immediately.

Small production volumes of untreated blanks mayalso be prepared by scrubbing the surface using anabrasive cleaner and a scouring pad, then rinsingclean with cold water, and drying immediately. Inthis case, the sheeting should be appliedimmediately.

If the sheeting is not applied immediately, theblanks should be treated with a vinyl pre-treatmentor equivalent so they will be ready to accept varioustypes of retroreflective sheeting or vinyl sheeting ata future date.

Generally speaking, the use of pre-treated blanks ispreferable. They are readily available from varioussuppliers. Pre-treated blanks eliminate the need topurchase, handle and store various chemicals andsolvents that require regulated procedures as setout in WHMIS and the need to keep up to daterecords of current MSDSs.

4.1.3 Plywood

Procedures for plywood sign blank preparation areillustrated in Flowchart B.3.

Plywood sign blanks must be at least mediumdensity overlay (MDO) plywood, as specified inOPSS 2002 or equivalent.

Plywood substrates require several preparationsteps before sheeting can be applied, to ensuredurability and longevity.

Surfaces must be smooth, impermeable andweather proof. All voids on the edges must be filledwith an exterior wood filler, such as plastic wood, oran exterior waterproof caulking with 10 to 20 yeardurability, then sanded and coated with anacceptable edge seal coating.

Substrate back and edges must be sealed orprimed. If substrate back and edges are to bepainted, ensure that the surface is clean and dustfree, and apply an exterior primer coat followed bya suitable exterior quality paint. Scuff sanding witha fine grit sandpaper may be required to ensure asuitable bonding surface. Remove any sandingresidue with a tack cloth.

Sheeting manufacturers’ recommended practice orrequirements to prime and paint the front face ofthe sign should be followed.

Colour tinting the primer coat the same as thefinish paint coat will assist in obtaining goodcoverage and colour continuity of the finishedproduct. Either good quality latex or oil base paintsmay be used. An advantage of latex paint is theeasier water clean up without the use of solvents.Oil base paints require degassing duringapplication, longer drying time, and solvents forclean up that must meet regulated handling andstorage criteria. Also oil base paints tend to be moreodour invasive.

4.1.4 Extruded Aluminum Panelsand Aluminum Overlay Sheets

Procedures for extruded aluminum panelpreparation are illustrated in Flowchart B.4;procedures for aluminum overlay preparation areillustrated in Flowchart B.5.

Extruded aluminum panels and overlay sheets arecommercially available in various widths, lengthsand profiles to suit requirements. The most



common extruded aluminum panels are ‘snaptogether’ and ‘bolt-together’ profiles. Figure 4.1shows a cross-section of a snap-together extrudedpanel. Figure 4.2 shows a cross-section of a bolt-together extruded panel. Aluminum overlay sheetsare used to repair or replace part or all of anextruded aluminum sign message withoutnecessarily having to repair or replace thecomplete sign. Note that a damaged sign may notalways be suitable for overlay sheets. Overlay sheetsshould be attached to a flat surface, and are usuallyused for maintenance refurbishing of an existingsign for a change of message.

Before sign sheeting can be applied, the panels oroverlay sheets must be prepared to conform tomanufacturers’ specifications for both substratepreparation and sheeting application.

Extruded aluminum panels and overlay sheetsshould first be cut to the appropriate size anddeburred. The aluminum surface must bedegreased and etched prior to having the sheetingapplied, by either immersing the panels or overlaysheets in a dip tank or washing and scuffing thesurface by hand. Specially designed dip tanks,used to degrease and etch the extruded panels oroverlay sheets, contain cleaning and etchingsolutions such as chromic acid or chromiumsulphate. Manufacturers’ instructions on time,temperature, and concentration are to be followed.Panels or overlay sheets must then be rinsedthoroughly using high-pressure spray with coldwater and left to dry.

Figure 4.1 – Snap-together Extruded Panel (cross-section)

Figure 4.2 – Bolt-together Extruded Panel (cross-section)

Source: Extrudex Aluminum

Source: Alcan Extrusions



When an extruded sign must be built in two ormore pieces, the sign design detail and themessage to be displayed should be examined.Select a combination of panels that will result in avertical joint that is not intersected by any signlegend (text, graphics, markers or logos).

Longer panels or overlay sheets not fitting a diptank may be prepared by scrubbing the surfacewith an abrasive cleaner and scouring pad andrinsing thoroughly with cold water. Manufacturers’recommendations should be followed.

If the panels or overlay sheets have not beenetched, the surface of the panel or sheet may haveto be scuff sanded prior to applying the sheeting, tosmooth any rough areas that may be present due tooxidization or corrosion while in storage or minordamage occurring during shipping or handling. Thismay be done by hand or using a belt or oscillatingsander with emery cloth or equivalent sandpaperdesigned for aluminum.

The panels or overlay sheets should be wiped witha tack cloth to remove dust just prior to applyingthe background sheeting.

4.1.5 Other Substrate Technologies

Plastic/Fibreglass

Plastics and fibreglass-reinforced laminates vary asto type and composition. While some are suitablefor use as sign substrates, others are not. Checksheeting manufacturers’ recommendations. Itshould be noted that any plastic or fibreglassreinforced laminate used as a sign substrate mustmeet or exceed the requirements set out in theOPSS specifications for aluminum or steelsubstrates. Preparation of plastic or fibreglassblanks should follow manufacturers’recommendations. Testing is recommended beforeadoption of such materials as a standard, to ensure

that the materials meet functional requirementsover a reasonable life cycle, including rigidity, lifeexpectancy, and sheeting adherence to thesubstrate.

Recycled Materials

Recycled materials are also coming into use as signsubstrates for some applications. Check sheetingmanufacturers’ recommendations. These materialsmust also meet or exceed the requirements set outin the OPSS specifications for aluminum or steelsubstrates. Testing is recommended beforeadoption of such materials as a standard, to ensurethat the materials meet functional requirementsover a reasonable life cycle, including rigidity, lifeexpectancy, and sheeting adherence to thesubstrate.

4.1.6 Random Testing

Random testing of all metal or plastic/fibreglasssubstrates should be conducted to ensure propersurface conditions. They should be checked visuallyand should include a water break test ifcontamination is suspected. The water break testfor oil or wax contamination simply involves pouringwater onto the surface of the blank. The watershould not bead, but should flow out to form asmooth uniform layer on the surface. Plywoodblanks should be visually inspected to ensurequality and conformance to specifications.

4.1.7 Storage of Substrates

All substrates should be stored appropriately toavoid damage and/or contamination. When storingand stacking material, avoid stacking heavy materialtoo high. This will prevent damage such as bendingof certain types of material due to excessive weight.Place wooden supports that are wide enough to



leave space between the lifts of material to alloweasy access for a forklift truck or other lifting device.This will also prevent possible damage of thematerial caused by this equipment when materialhas to be moved.

If possible, the material should be stored indoorswhere it can be kept dry. If storage of the material isoutside, substrates such as plywood, treatedaluminum or treated metal blanks should becovered and kept dry.

4.2 Background Sheeting Application

Procedures for background sheeting application areillustrated in Flowchart B.6.

For proper application of sheeting, users shouldfollow the recommendations of sign sheetingmanufacturers and of manufacturers of signsheeting applicators. This may also be necessary tomaintain warranty provisions.

For better sign quality and colour uniformity, signsheeting from two different rolls should not be usedon the same sign blank or sign without firstchecking for colour/brightness variability, at leastunder daylight conditions, and preferably underboth daylight and nighttime conditions. This issuearises only with large signs.

4.2.1 Pressure Sensitive Sheeting

Pressure sensitive sheeting is generally appliedusing a mechanical squeeze roll applicator (Figure4.3) or a hand squeeze roll applicator (Figure 4.4).

Figure 4.4 – Hand Squeeze Roll Applicator

Source: Arges Training & Consulting and City of Toronto Sign Shop

Figure 4.3 – Mechanical Squeeze Roll Applicator

Source: City of Guelph

Mechanical Applicators

Mechanical applicators are well suited to highvolume production with both flat substrates (metalor plywood sign blanks) and extruded panels. Thefollowing procedures are recommended:



Figure 4.5 – Mechanical Applicator Sheeting Tension

Source: 3M Company, St. Paul, MN

• Using the mechanical applicator, the substrate isfed into the applicator between 2 rollers, anupper roller and a lower roller. These rollers aregenerally made of rubber although the lowerroller may be made of metal. (Note that the lowerroller may also be segmented to accommodateextruded aluminum panels).

• The sheeting stock and the take up spool for thesheeting liner (backing) are located above andparallel to the rubber rollers. As the substrate isfed between the rotating rubber rollers, thesheeting is fed from above while the liner isremoved and spooled onto the take up roll.

• The sheeting being fed from above must have thecorrect tension. Tension adjustments must becorrect for proper application; tension that is tootight may cause the sheeting to stretch or tear orcrack, and tension that is too loose may result inthe sheeting wandering off line or wrinkling.Figure 4.5 illustrates proper mechanicalapplicator sheeting tension.

• As the substrate advances through the applicator,the sheeting also advances at the same speedwhile uniform pressure from the upper and lowerrollers adheres the sheeting to the substrate.Pressure contact from the rubber rollers must be

correct according to manufacturer’s specificationsand uniform across the entire width of thesubstrate to ensure proper adhesion withoutwrinkles or air bubbles.

• A heating accessory bar should be used toslightly warm the substrate and sheeting justprior to application. It is located a few centimetresfrom the rubber rollers where the substrate meetsthe sheeting. (Note that for some sheetingmaterials, the manufacturer recommendsdirecting the heater towards the substrate but nottowards the sheeting.)

• A feed table and exit table are recommended toassist in supporting larger substrates. Ideally,these tables are at least 1200 mm by 2400 mm(4 feet by 8 feet) and some have adjustable legsfor height. The top of the table has a series ofrollers that span the width and run the entirelength of the table. This accommodates feedingand removal of the substrates since they caneasily be rolled into position and removed.

• As the substrate is fed in one end of theapplicator and exits on the other end, the locationto set up the mechanical applicator must provideenough space to accommodate the longest



substrate that will ever be used. (i.e., a 7.2 m(24 foot) aluminum extrusion would requireapproximately 18 m (60 feet) minimum of totaloperating length).

• When sheeting is applied to extruded aluminumpanels, the lower roller must be segmented toallow for the profile of the panel to pass betweenthe rollers, providing a flat surface for thesheeting to be applied. A special attachmentcentre guide of small rollers at right angles to therubber rollers secures both sides of the centre ribof the panel. This ensures that each panel is fedin straight and positioned properly so the entiresurface is covered with the sheeting. The exit endof the table should have a series of edge rollersthat gradually wrap the sheeting around the edgeof the panels.

• When sheeting is applied to flat stock, fenceguides on the feed side at right angles to therubber rollers should be used and adjusted. Thisensures that each piece is fed in straight andpositioned properly so the entire surface iscovered with the sheeting.

• Adjust pressure and check heating accessorytemperature. Once the application is set up foreither flat stock or extruded panels, the sheetingstock and take-up spool must be set up.

• Position the sheeting stock on the upper feedspool and a used sheeting core on the take upspool. Feed the sheeting under the supply roller.Peel the liner (backing) off and attach it with tapesecurely onto the take-up spool. Drape thesheeting over the upper rubber roller and trimexcess. Be sure to leave enough material that itwill cover the lead edge of the substrate.

• Place the first substrate on the feed table and rollup to the upper and lower rubber rollers comingin contact with the sheeting. Start the applicatorand feed the substrate in while wiping with atack cloth. Feed additional panels while wipingwith a tack cloth.

• On the exit end of the rollers, trim the excessmaterial from the edges and the ends to separatethe substrates. (Note that extruded aluminumpanels will only need the ends trimmed, as theedges will be rolled over by the edge rollerattachment). Stopping the machine temporarilyon the exit side of the rollers will allow for easierseparation and trimming of the substrates.

• Remove the sheeted material from the exit tableand stack.

• While the applicator is running, continue tomonitor the tension of the sheeting and adjust asrequired.

• When coming to the end of a roll of sheeting, rollthe entire material onto the substrate. Once thishas been adhered and has extended past therollers on the exit end, stop the machine andreverse to bring the end edge of the sheetingback to the feed side of the rollers. Install a newstock roll and attach as explained above. Positionmaterial and substrate to allow for an overlap jointand continue the operation.

Hand Squeeze Roll Applicators

Hand squeeze roll applicators are generally used forlow to medium production applications. Thefollowing procedures are recommended:

• Using a hand roller applicator, the substrate is fedbetween a lower and upper roller driven by handcrank. The upper roller is either mechanically orpneumatically adjustable to allow proper



adhesion pressure. Crank a substrate between therollers and adjust pressure so it is uniform acrossthe entire width of the substrate.

• Prior to the application of background sheeting,cut appropriate pieces of sheeting slightly largerthan the substrate to be covered.

• There are two common methods of applyingbackground sheeting to the substrate:

• the first method is called the split liner method,and is generally considered the easier methodto apply. Place a piece of sheeting face up ontop of the substrate, so that the sheeting coversthe entire substrate. Slide the substrate andsheeting between the rollers, to about themidpoint of the substrate length. After carefullylining up the sheeting over the substrate,tighten the rollers. Pull back one half of thesheeting, over the rollers, and peel off thesheeting backing. Then roll the sheeting ontothe substrate for that half of the sign, throughthe rollers, starting at the centre and rolling outto the sign edge. Repeat the process for theother half of the sign. See Figure 4.6.

• the second method applies the sheeting fromone end of the sign length to the other, andrequires more care and experience to achieve asatisfactory result. Position the substrate on thefeed end of the rollers and place a piece ofsheeting face up on top of it. Be sure thesheeting is positioned to cover the entiresubstrate. While keeping the sheeting in place,peel back the leading edge of the sheetingapproximately 50 mm and trim off the backing.Adhere the 50 mm strip of sheeting to the leadedge of the substrate. Move the substrateforward to butt against the rollers and thencrank in this material approximately 25 mm tosecure. Drape the remaining sheeting back overthe top roller. Take the backing liner near therollers and while holding it, crank the substrateand sheeting through the rollers.

• Trim the edges and stack.

• Repeat the process. If multiple small size blanksare being covered, the above process may beused or several of the blanks may be placed on aplywood substrate and covered at the same time.

Hand (Squeegee) Application

Smaller applications may be done by hand, asfollows:

• Position the appropriate slightly over-sized pieceof sheeting on the blank and secure it with apiece of tape either at one end of the blank (forsmall blanks) or across the width of the blank, atthe centre of the blank (for larger blanks).

• Raise one end of the sheeting and remove about25 to 50 mm of the backing liner.

• Place the sheeting back on the blank and applypressure to make it adhere by using a squeegeeor a hand roller.

Figure 4.6 – Application of BackgroundSheeting: Hand Squeeze Roll Applicator




• Remove the tape.

• Raise the remaining piece of the sheeting, ifapplicable, and remove the backing liner slowlyas the sheeting is rolled or squeegeed into place.Care must be taken to ensure proper adhesionwith no air bubbles.

Splicing

Splicing of sheeting is generally not recommended,if it can be avoided. When splicing of sheeting isrequired, horizontal splicing is generally preferred tovertical splicing since, if properly lapped, it willeffectively shed moisture. With some sign substratesizes, sheeting widths, and applicator widths,horizontal splicing may also be easier and morestraightforward when applying sheeting to longhorizontal sign panels. If horizontal splicing is used,the top piece of sheeting on the sign shouldoverlap the lower piece of sheeting, to avoidmoisture accumulation. However, there may besome situations where vertical splicing is necessary.

Colour matching of spliced material is importantfor daytime and night time appearance, somaterial with the same batch number should beused whenever possible. Manufacturers’recommendations for colour matching of splicedmaterials should be followed.

4.2.2 Heat Activated Sheeting

Heat activated sheeting is rarely used anymore andhas virtually been replaced by pressure sensitivesheeting.

This material is applied using a vacuum applicator,which removes the air between the sheeting andthe substrate and then uses heat lamps to activatethe adhesive to the substrate.

4.3 Sign Assembly(Extruded Aluminum Panels)

Procedures for extruded aluminum sign assemblyare illustrated in Flowchart B.9.

4.3.1 Bolt-together Panelsand Snap-together Panels

In Ontario, extruded aluminum panels are used forlarge types of signs in most cases, rather thanstandard flat stock substrates. As these panels areavailable in different widths and lengths, a sign canbe custom built by varying the number of panelsused. Assembly of these panels takes place afterthe background sheeting has been applied. Boththe bolt-together and snap-together extruded panelsare assembled in virtually the same way; only theconnection of the panels to each other differs. Inboth cases, the 300 mm (one foot) wide or150 mm (six inch) wide sign panels runhorizontally.

Users of snap-together panels have done so formany years, and continue to do so because ofexperience and familiarity with this process, citingadvantages of faster assembly and lower assemblylabour costs. Most sign fabricators use bolt-togetherpanels, and cite the following advantages:

• T-bars or Z-bars used in assembly of the signs aremore easily adjustable in the field.

• Signs are more easily assembled, especiallylonger signs.

• Signs are more easily disassembled and recycled.

Extruded sign assembly may be accomplishedthrough use of the following process:



• The appropriate number of panels is laid facedown on a series of saw horses or a flat assemblytable, which should be covered with foampadding or carpet or similar material to protectthe sheeting on the panels.

• Bolt-together panels are connected horizontally bybolts through a series of slotted holes running thelength of the panel edges.

• Snap-together panels are connected horizontallyby snapping the panels together by the ribs thatare part of the panel design and run the fulllength of the panel. With the snap togetherpanels the panel edge that is 90 degrees will bethe top of the sign.

• Once all the panels are connected using eitherdesign, the assembly is completed by installingeither aluminium T-bars or Z-bars, bolting them tothe panels at right angles to the horizontal. Thebars must run the full height of the sign plus50 mm (2") at the bottom and should have a holedrilled at the top of each bar to facilitate hoistingof the sign. The bars also allow for the mountingof the sign on the sign structure, either by boltsor clamps, and should be drilled accordingly.Figure 4.7 illustrates snap-together extrudedpanels assembled with T-bars. Figure 4.8

Figure 4.7 – Snap-togetherExtruded Panels assembled with T-bars

Source: Arges Training & Consulting and Harpar ManagementCorporation

Figure 4.8 – Bolt-togetherExtruded Panels assembled with T-bars

Figure 4.9 – Extruded Panels assembled withZ-bar, for attachment to Trichord Sign Structure


Source: MTO

illustrates bolt-together extruded panelsassembled with T-bars. Figure 4.9 illustratesextruded panels assembled with Z-bars, forattachment to a trichord sign structure.

• The T-bars or Z-bars must be cut to length priorto attachment to the sign. It is also advisable todrill the hole in the top of each bar as well as theholes for the mounting brackets prior toattachment to the extruded panels. Thepositioning of these bars will be dependent onthe type of structure on which the sign will bemounted.



• Measure the spacing of the T-bar or Z-bar alongthe length of the top and bottom panels.

• For snap-together panels, place the T-bar or Z-barin position and hold in place with a clamp or vicegrips. Drill and attach the T-bar or Z-bar to theribs of the extruded panels using 32 mm x 8 mm(1 1/4“ x 5/16”) stainless steel hex head boltswith stainless steel hex head nuts and stainlesssteel lock washers. These bars also give theassembled sign panels rigidity and stability.

• For bolt-together panels, pre-drill the T-bar orZ-bar to accommodate the attachment bolts.Slide the bolts for all bars in the slots and alignthem across the back of the sign. Place the firstbar on the back of the sign, on the bolts, andtighten it down, the top and bottom bolts first,and then the others. Either start with the first barat one end of the sign and work across, or startwith a bar at/near the centre and work outwards.These bars also give the assembled sign panelsrigidity and stability.

• If this extruded sign is a tab, follow the sameprocedure for either snap-together or bolt-together panels, with the following exception.This particular sign uses a 9.5 mm x 50 mm x1270 mm (3/8" x 2" x 4'-2") aluminum flat bar toattach the panels and also to attach it to thelarger sign. Cut the flat bar to length, and drill andattach it to the extruded tab using the appropriateprocedure and bolts for snap-together or bolt-together panels, as described above.

Note: If the MTO standard snap-together panelsare used, this particular tab sign is built with the90 degree edge as the bottom of the sign. Thistab can be installed in the shop or in the field.

• Once completely assembled, the sign is eitherflipped over so it is facing up or placed on aneasel in preparation for application of the legend.

4.3.2 Aluminum Overlay Sheets

Aluminum overlays are flat stock aluminum sheetsused to refurbish existing signs or as a lower costalternative to a new extruded aluminum sign.

Overlay sheets for this purpose have a thickness of1 mm (0.040 inches) and come in various widths,usually 900 mm (3 feet), 1200 mm (4 feet) and1500 mm (5 feet), and lengths, usually 1500 mm(5 feet), 1800 mm (6 feet), 2100 mm (7 feet),2400 mm (8 feet) and 2700 mm (9 feet).

Note: Overlay sheets must be ordered in Imperialmeasurements as they are used to cover extrudedaluminum signs, which are all Imperialmeasurements. The widths and lengths shown areImperial; the metric values are nominal equivalents.

Overlay sheets have the background sheeting andlegend applied prior to being attached to theexisting extruded sign. Overlay sheets may beattached in the field to refurbish an existing sign orin the shop by being attached to a reclaimedextruded aluminum sign. In either case, the sheetsare attached to the extruded sign with 3 mm (1/8inch) aluminum pop rivets and 4.5 mm (11/64inch) stainless steel truss head bolts. Figure 4.10Ashows a sign where small overlay panels have beenused to show revised population; Figure 4.10Bshows a sign where the complete sign is overlaid toshow different messages in summer and winter.

The sheets are held in position while drilled andpop rivets are installed to secure the overlay sheetto the extruded sign. The rivets are installed aroundthe perimeter of the overlay sheet approximately150 mm apart.

Note: A minimum of 2 rivets per extruded panelmust be used vertically along the overlay sheetedges to attach the overlay sheet to each extrudedpanel.)



generally from left to right. Care must be taken toensure that the first sheet is aligned squarely, aserrors will be carried across the entire sign. If thesheets are being installed in the shop on areclaimed extruded sign, the entire sign should belaid flat on saw horses and all the sheets may thenbe laid out on top prior to installation.

4.4 Legend Preparationand Application

Legend preparation and application may beaccomplished in a variety of ways. Not all methodsare described in Book 2. The methods includedhere are considered to be representative ofcommon industry practice.

4.4.1 Screen Printing

Procedures for legend application (screening) areillustrated in Flowchart B.7. Procedures forconstruction of a screen frame are illustrated inFlowchart B.7A.

Screen printing is an efficient, cost-effectivemethod of producing large quantities of identicalsigns. Durable quality signs can be ensured byusing the proper inks and appropriate techniques.

Screen printing requires a screen frame consistingof a screen fabric stretched tightly and uniformlyand fastened to a rigid metal or wood frame. Thetype of screen fabric used will depend on the typeof ink being used, and the screen mesh size usedfor a particular type of ink should followmanufacturers’ specifications. The screen framemust be large enough to allow a minimum 150 mm(6 inch) wide area between the frame edge and theprinting area. A stencil film, as recommended bythe sheeting and ink manufacturers, is cut out tothe desired sign image and then applied to the

Figure 4.10AOverlay Sheet on Extruded Panel Sign

Source: Arges Training & Consulting and MTO

Source: Arges Training & Consulting and MTO

Figure 4.10BOverlay Sheet on Extruded Panel Sign

In addition to the rivets, corner bolts are attached ineach of the four corners of the overlay sheet usinga 4.5 mm (11/64 inch) stainless steel truss headbolt with stainless steel hex nut and stainless steelstar lock washer. A 1200 mm (4 feet) wide overlaysheet should also have additional rivets installedthrough the centre of the sheet vertically from topto bottom. In the field, the sheets must be installedwhile in vertical position, one sheet at a time,



screen mesh. All areas and edges should be sealedwith an appropriate filler. The only open mesh areasshould be the desired sign message where the inkwill pass through.

A screening table must be flat and large enough tosupport the entire screen frame and have hinges tohold the frame in position. Vacuum screening tablesare also available and are designed specifically forthis process.

One method for screen printing signs is as follows:

• When preparing to print material, place thescreen frame on the table and fasten securely tothe hinges.

• Material to be screened may be either reflectiveor non-reflective sheeting cut to size, or it may bea blank with the background sheeting appliedto it.

• Position the material beneath the screen.

• Use tape guides along two adjacent edges of thematerial to keep subsequent sheets or blanks inproper register. Tape guides work well forscreening flat sheets of material. When screeningonto a blank, the guides should be almost asthick as the blank and wide enough to supportthe width of the squeegee being used. This willprevent damage to the screen. Be sure the guidesare not higher than the sheeting or the blank asthis will affect the printing performance by notallowing the screen to properly contact thematerial as the squeegee is passed over it. SeeFigures 4.11 and 4.12.

• A squeegee is used to deliver the ink across themesh. The squeegee should be a sharp, mediumto hard rubber blade and should be long enoughto cover the entire print area plus 50 mm(2 inches) on either side.

Figure 4.11 – Screen Printing Set-up


• When screening sheets that are not applied to asubstrate, the sheets should be held in placeusing a vacuum table, or a low tack adhesivewhen a vacuum table is not being used.

• Off-contact screening gives the best and sharpestprint. Placing foam rubber blocks on the frameedges causes the mesh and ink to contact theprint area briefly as the squeegee passes.

• Mix or thin the ink if required, following themanufacturers’ specifications and be sure to haveenough ink to complete the entire job. Have someclean up solvent ready to wipe up spills or toclean up misprints or leaks in the screen.



• Pour the ink into the frame area at one end orside.

• Place plain unwaxed kraft paper (or similar; thescrap backing paper from the reflective sheetingmay also be used) under the frame.

• Flood the screening area by drawing ink lightlyacross the mesh using the squeegee, notallowing the mesh to contact the materialbeneath.

• Then draw the squeegee back across the meshfirmly on a slight angle making sure the meshcontacts the material beneath. This causes theink to pass through the open mesh, making theimpression on the material beneath.

• Print two or three different times on the paper tocheck for print quality. This also allows the screento become saturated with ink in preparation forthe actual printing.

• Once the print quality is satisfactory, and thereare no leaks, the final printing can begin. Place apiece of sheeting or blank beneath the frame andrepeat the above procedure, beginning withflooding the screen.

• Remove the printed substrate or sheet by liftingthe frame just enough to remove the sheeting orblank and place on a drying rack. See Figure 4.13.

• Provide air circulation as recommended by theink and sheeting manufacturers.


Figure 4.12 – Screen Printing



• Place a new piece of material beneath the framein the register and repeat the process.

Clean-up

• Upon completion of the job, the excess inkshould be removed and placed in a container andthe screen should be cleaned immediately withsolvents recommended by the manufacturer.

• To clean the screen while it is still attached to thescreen table, place several sheets of kraft paper ornewspaper beneath the frame. This will be usedto soak up the solvent that will pass through theopen mesh during the clean up.

• Pour the appropriate solvent into the frame anduse rags to wash the screen and remove the inkresidue.

• Dry with clean rags, then remove the paper underthe frame and dispose of it.

• Repeat the process until the frame is thoroughlycleaned.

• If a washing station is available, remove the frameand rinse clean with the solvent and drycompletely.

• Once cleaned and dried, place the screen in asecure area to prevent damage, for future use.

• If this screen was used for a one-time job, afterthe ink has been removed, the image can bewashed out and the screen frame can be dried.This frame should then be placed in a secure areato prevent damage, for future use.

4.4.2 Direct-applied Copy

Letters, numbers and symbols can be cut usingseveral techniques. Procedures for legendapplication (direct-applied copy) are illustrated inFlowchart B.8.

Hand-cut Copy or IndividuallyCut Legend Characters

Hand-cutting using cardboard templates is onemethod. This is done by tracing the outline of aletter or symbol (legend) on the liner (backing) sideof the sheeting and then cutting this image outusing a sharp knife/blade.

• Legend cut individually from templates is placedon the sign surface to produce a specificmessage. It should be spaced properly to producea balanced and legible sign message.

• Once the legend is in place, fasten it to the signwith a small piece of masking tape along thebottom to hold it in position so it is ready to applyusing transfer tape. Transfer tape is a low tackmaterial that is used to hold sign legend in place

Figure 4.13 – Drying Racks




while allowing the removal of the backing liner.Follow manufacturers’ recommendations, as thetype of transfer tape to be used varies with thetype of reflective sheeting material.

• Once the liner has been removed and the signlegend has been secured to the sign face, thetransfer tape is easily removed.

• Using a transfer tape slightly larger than thelegend to be transferred, squeegee or roll thisonto the legend. Pull the transfer tape towardsyou with the legend, allowing it to hinge alongthe bottom.

• Remove the backing liner from the legend andmove back into position.

• Squeegee or roll the legend to adhere to the signsurface, then remove the transfer tape. Be sure toremove all air bubbles.

Note: In applying legend to overlay sheets, placethe overlay sheets on a work table large enough tosupport the full height of the overlay sheet and toaccommodate several sheets side by side. Hold thesheets together with masking tape to preventrelative movement during legend application.

Computer-cut Copy

A more current and common method is computer-aided cutting of copy. By use of a computer with theappropriate software, sign legends can be designedand transferred to a plotter/cutter that will cut thelegend on reflective or non-reflective sheeting. Thisprocess will also cut screen printing film.

• If a sign message is designed on a computer andcut on a plotter/cutter, it can already be spacedproperly, and often is cut this way.

• After the message has been cut, weed out thematerial that is not part of the message. Weedinginvolves picking off the unwanted material of thesign face such as the background around thelegend including certain parts of some letters, i.e.,the centre of the letters O, P, R, D etc. Removethis material carefully while not disturbing thedesired message. See Figure 4.14.

• Position the legend, including the backing paper,on the sign face or on a cutting table, and rolltransfer tape over the material with an overlap ofapproximately 50 mm (2 inches). See Figure4.15. Tape the sign legend and transfer tape tothe face of the sign. See Figure 4.16. Pull thismaterial back, hinging on the transfer tape, andremove the backing paper. See Figure 4.17.

• Return the sheeting to its proper position and rollor squeegee to adhere the message to the signface, being careful to remove all air bubbles. SeeFigure 4.18.

• Remove the transfer tape to leave the desiredmessage on the sign face. See Figures 4.19and 4.20.

Note: In applying legend to overlay sheets, placethe overlay sheets on a work table large enough tosupport the full height of the overlay sheet and toaccommodate several sheets side by side. Hold thesheets together with masking tape to preventrelative movement during legend application.



Figure 4.17Removal of Backing from Sign Legend

Figure 4.14 – Weeding Computer-cut Legend

Figure 4.19 – Removal of Transfer Tape

Figure 4.18 – Legend Application to SignBackground with Hand Squeegee

Figure 4.20 – Finished Sign

Figure 4.16Taping of Legend and Transfer Tape to Sign

Figure 4.15Transfer Tape Application to Sign Legend




Figure 4.2 – Applicators

Reverse-cut Transparent Film

An alternative to the use of screen printing or of thetypical application of direct-applied copy,particularly where only a few signs are to be made,is the use of reverse-cut transparent film. Considerfor example a sign which is to have white legend ona coloured background, such as a STOP sign.Screen printing becomes less attractive as thenumber of signs decreases. In the typicalapplication of direct-applied copy, the letters are cutfrom white reflective sheeting and applied over thecoloured reflective background. However, this resultsin use of a considerable amount of both white andcoloured reflective material. With reverse-cuttransparent film, white reflective sheeting is used forthe background, and the legend is reverse cut froma sheet of coloured transparent film (which is lessexpensive than the reflective sheeting), and appliedover the background sheeting. Reverse cut simplymeans that the cut letters are removed rather thanthe material that is around them, and theremaining, surrounding coloured material is appliedto the white background, allowing the white toshow through. The transparent coloured film servesas a colour filter much the same as screening ink,but is often less expensive and quicker. The film isalso known as electronic-cuttable overlay film. Ifused, manufacturers’ recommendations shouldbe followed.

Figure 4.6 and Figures 4.21 to 4.29 illustrate theprocess of sign fabrication by this method, andusing a hand squeeze roll applicator. The first step,the application of the retroreflective whitebackground sheeting, is shown in Figure 4.6. Figure4.21 shows the reverse-cut computer cutting of thelegend on transparent coloured film. Figure 4.22shows the weeding of the computer-cut legend.Figure 4.23 shows the application of transfer tapeto the reverse-cut transparent sheeting. Figure 4.24shows the positioning of the transfer tape andtransparent sheeting (with backing) on the whitebackground sheeting already applied to thesubstrate. Figure 4.25 shows the stripping of the

backing from the reverse-cut transparent sheeting,for the first half of the sign. Figure 4.26 shows thesame for the second half of the sign. Figure 4.27shows the application of the transfer tape andreverse-cut transparent sheeting (backing removed)to the white background sheeting on the substrate.Figure 4.28 shows removal of the transfer tape, andFigure 4.29 shows the completed sign.

Figure 4.21Computer Cutting of Legend on Transparent Film

Figure 4.22 – Weeding of Computer-cut Legend



Figure 4.23 – Application of TransferTape to Reverse-cut Transparent Sheeting

Figure 4.24 – Positioning of Transfer Tape andTransparent Sheeting (with backing) on Reflective

White Background Sheeting on Substrate

Figure 4.25 – Stripping of Backing fromReverse-cut Transparent Sheeting (first half)

Figure 4.26 – Stripping of Backing fromReverse-cut Transparent Sheeting (second half)

Figure 4.27 – Application of Transfer Tape andReverse-cut Transparent Sheeting to Reflective

White Background Sheeting on Substrate

Figure 4.28 – Removal of Transfer Tape

Figure 4.29 – Finished Sign




4.5 Storage of Partially Completedand Completed Signs

Both partially completed sign blanks that arecovered with sheeting and completed signs with asheeting legend should be stored indoors and ontheir edge in suitable racks. They can also be storedflat, but only in small quantities and for a shortperiod of time, and they should be stacked face toface and back to back. Place a protective paperbetween the sheeted sign faces to prevent damage.

Note: As plywood signs have painted backs, besure they are dried thoroughly to prevent stickingwhen they are placed back to back. Depending onthe type of blank being stored flat, limit the numberof signs per stack and the duration of storage, toprevent damage. As the weight increases thepotential for damage increases.

Signs that have a screened legend must bethoroughly dried prior to storage. These should bestored on edge. They may be stored flat ifnecessary. If they are to be stored flat, they shouldbe stored face to face and back to back. Anappropriate type of unwaxed paper should beplaced between the faces of the signs to preventthem from sticking together. Again, when storingsigns flat, limit the number of signs per stack andduration of storage, to prevent damage. If signs arestacked and stored flat, the crushing may result in aloss of reflectivity, even after relatively short storageperiods. Also, the weight of a large number of signsin a stack may result in the signs sticking together.This may result in damage when the signs areseparated.

Sheeted aluminum overlay and completedaluminum overlay with legend applied should bestored on edge until ready to install.

Completed extruded aluminum signs should bestored on edge in appropriate racks.

Signs sheeted with Type III, IV, V, VI, VII VIII or IXreflective sheeting should be stacked on edge inappropriate racks. Special care is required if they areto be stacked in a flat position. They should bestacked face to face, then back to back. A specialmicro foam protection should be placed betweenthe sign faces to prevent damage. Also, limit thenumber of signs per stack as excessive weight willcause damage by compressing the cells of the TypeIII, IV, V, VI, VII VIII or IX sheeting. Loss of reflectivitycan occur, even after relatively short storageperiods.

4.6 Sign Fabrication Process(flowcharts of procedures)

The processes for fabricating signs of various types,as described in Sections 4.1 to 4.5, are illustratedin Flowchart B, a collective term which includesFlowcharts B.1 through B.9.

B.1 Overview, Sign Fabrication ProcessB.2 Metal Blank PreparationB.3 Plywood Blank PreparationB.4 Extruded Aluminum Panel PreparationB.5 Aluminum Overlay PreparationB.6 Background Sheeting ApplicationB.7 Legend Application: ScreeningB.7A Construction of a Screen FrameB.8 Legend Application: Direct Applied CopyB.9 Extruded Aluminum Sign Assembly



Flowchart B.1 – OverviewSign Fabrication Process



Flowchart B.2 – Metal Blank Preparation



Flowchart B.3 – Plywood Blank Preparation



Flowchart B.4 – Extruded Aluminum Panel Preparation



Flowchart B.5 – Aluminum Overlay Preparation



Flowchart B.6 – Background Sheeting ApplicationMechanical Applicator or Hand Roller – Metal or Plywood Blanks or Extruded Aluminum Panels



Flowchart B.7– Legend Application: Screening



Flowchart B.7A – Construction of a Screen Frame



Flowchart B.8 – Legend Application: Direct-applied CopyMetal or Plywood Blanks and Extruded Aluminum Panels



Flowchart B.9 – Extruded Aluminum Sign Assembly



5. Master Sign Library

An important part of Book 2 is the electronicMaster Sign Library (MSL), packaged on a CD-ROMin the back cover of this Manual. Because of spacelimitations, a hard-copy paper library of all standardsign pattern templates was not included. The MSLhas been created with Adobe® Illustrator® 9.0. Aswell, the MSL has been created with Adobe®

Acrobat®, permitting users to make hard copies ofselected sign pattern templates using AdobeAcrobat Reader, even if they do not have AdobeIllustrator. Section 5.1.3 details electronic standards.

5.1 Master Sign Library Elements

The Master Sign Library contains the following:

(1) The sign patterns for all OTM signs, using astandard (common) sign pattern template.See Section 5.1.2 (Sign Pattern Template).

(2) A Sign Parts Library (SPL), containing varioussign parts (e.g., arrows, crowns, shields) usedto create customized standard signs (such asdirectional guide signs) to a standardtemplate, as well as non-standard signs. SeeSection 5.1.4 (Sign Parts Library).

(3) A list of all standard MTO sign blanks, alongwith detailed dimensions and drawings ofthose standard sign blanks used for metalsigns. See Section 5.1.5 (Sign Blanks).

Font sets (all numerals and alphabet characters) arenot included in the MSL, as they are copyrightedand must be purchased separately by the user (seeSection 5.1.3).

5.1.1 Sign Classes

The organization of the sign patterns in Book 2,including the Master Sign Library, follows the signclasses in Books 5 to 9 of the Ontario TrafficManual. Although Books 8 and 9, based onthe KHGSPM, have not yet been published, mostKHGSPM directional and information signs areincluded in the MSL.

• Regulatory Signs (Book 5)Ra Right-of-way Control SignsRb Road Use Control SignsRc Miscellaneous Control Signs

• Warning Signs (Book 6)Wa Physical Conditions Warning SignsWb Traffic Regulations Ahead SignsWc Pedestrian and Intermittent Hazard Signs

• Temporary Conditions (Book 7)TC Temporary Conditions Warning Signs

• Directional and Information Signs (Book 8)Gd Destination and Assurance SignsGf Freeway Guide SignsGh Highway Numbering Change SignsGI Municipality, County, District Signs on

HighwaysGor Police, First Aid, Telephone, Picnic, Travel

Information SignsGr Channelizing & Turn-off Signs, Urban Street

Name SignsGrr Private Roadway SignsGs Miscellaneous Guide SignsMf Hospital, Airport, Bus Terminal, Rail Station,

Ferry, Travel Information MarkersMh Route Markers, Direction

and Turn-off Markers



• Tourism and Commercial Signs (Book 9)T Tourism Attraction Signing (freeways and

non-freeways)L Logo signing for motorist servicesMunicipal & Institutional Attraction Signing (not

signed from highways)Commercial Signing

5.1.2 Sign Pattern Template (SPT)

A standard (common) sign pattern template is usedfor the signs in the Master Sign Library. The signpattern template displays the appearance of thesign. Attached to each sign pattern template, forstandard regulatory, warning, and temporaryconditions signs, are accurately drawn 1/10 scalecut image(s) in Adobe Illustrator 9.0, suitable to beused for the fabrication of the sign. There is aseparate cut image for each size of standard signshown in the OTM. The cut image provided issufficient to recreate the entire sign. The signpattern template also contains importantinformation about the sign, including:

• sign name;

• basic sign number, e.g., Ra-1;

• sign numbers for each of the standard sizes givenfor that sign (this is the basic sign numbertogether with the overall dimensions of the sign).See also Section 1.2 (Sign Numbering System);

• sign blank number;

• dimensions of the various component elementsof the sign (e.g., text lines, symbols, markers,arrows);

• the cut image reference for a standard sign of agiven size (this reference is the basic sign numbertogether with the overall dimensions of the sign,and is shown beside the cut image to identify it;also shown with the cut image reference is thescale factor of 1:10);

• the sign element (background, border, or legend),colour and minimum reflective sheeting;

• the font series used for word legends; and

• special notes, including a note, for specificregulatory signs, that they must comply with theHighway Traffic Act (HTA) and its Regulations.

For a square, rectangular, octagonal or trapezoidalsign, the vertical dimensions for the sign elementsshown on the SPT will add up to the overall verticaldimension of the sign.

For a diamond-shaped warning or temporaryconditions sign, the overall dimension of the signrefers to one of the sides of the diamond. However,the vertical dimensions for the sign elementsshown on the SPT add up to the diagonaldimension of the diamond-shaped sign, not to thedimension of the side of the sign, even though theside dimension is shown below the line (to indicatethe sign size to which those vertical sign elementdimensions refer). For example, for a 900 mm x900 mm diamond-shaped sign, the slightlyrounded vertical dimensions of the sign elementswill add up to 1230 mm.

In Book 2, the term “Standard Signs” is used torefer to those signs in the Master Sign Library forwhich the cut images may simply be used as is orwith very minor change (e.g., speed limit signnumeral 90 instead of 50 as shown). Mostregulatory, warning, and temporary conditions signs(Books 5, 6, and 7 respectively) are standard signs.



The term ”Customized Standard Sign” is used torefer to those signs which are in the Master SignLibrary (shown on a sign template), but which needto be adjusted to accommodate the specific localsign message. Most customized standard signs aredirectional guide signs and need to be designedaccording to the sign design rules and sign designprocess outlined in Sections 2.14 and 2.15. Signtemplates are provided in the MSL, as illustrativeexamples only, for directional guide signs and fortourism and commercial signs (Books 8 and 9respectively). The images shown for these signscannot simply be used as cut images to create asign. On most large directional guide signs, astandard border width is used over a specific rangeof sign sizes, so that even if the size of the sign ischanged, the border width remains the same.

Figure 5.1 – Sign Pattern Template for Rb-1 Figure 5.2 – Sign Pattern Template for Gd-10B

Some signs will have a standard height and avariable width, depending on the message. Othersigns will have both variable height and variablewidth. The sign template for these signs showssimilar information as is listed above, but thepattern will have to be adjusted, depending onnumber of lines, length of words, and use ofvarious parts from the Sign Parts Library. SeeSection 5.1.4 (Sign Parts Library). That is, the signpattern provides a starting point, but the sign mustbe customized and properly designed for theparticular situation.

The term “Non-standard Sign” is used to refer tosigns which are not included in the MSL, andwhich need to be designed by the user. Someexamples of these are special warning signs. Note



however, that non-standard signs still need to followbasic rules of design. These include colour andshape coding consistent with the type of sign(regulatory, warning, temporary conditions,directional, information, or tourism andcommercial), and use of the Sign Parts Library (asappropriate) and the principles and rules for signdesign and layout.

Examples of sign pattern templates are shown inFigures 5.1 and 5.2.

5.1.3 Electronic Standards

Adobe® Illustrator®

All standard sign patterns and all parts of the SignParts Library were created using Adobe Illustrator9.0 (.ai format) at a scale of 1/10. Illustrator iswidely used in the sign fabrication industry, and istherefore considered to meet the needs of mostusers. Any user with Adobe Illustrator 9.0 or higherwill be able to open and use the MSL .ai files. Userswith older versions of Adobe Illustrator can buy anupgrade at a modest cost. Many sign-cuttingsoftware packages, used with sign-cuttingmachines, readily accept Adobe Illustrator files.

Adobe® Acrobat®

All drawings in the MSL have also been createdwith Adobe Acrobat (.pdf format). Acrobat Reader isavailable free of charge from Adobe atwww.adobe.com.

Fonts

Fonts are not included in the MSL CD-ROM, as theyare copyright protected and must be purchasedfrom a font supplier.

The fonts in the Illustrator files have been convertedto outlines, therefore it is not necessary to installfonts except when creating customized standardsigns (directional and information guide signs,tourism and commercial signs, and sometemporary conditions contract identification signs)and signs with variable numerals (e.g., maximumspeed signs, distances, height clearances,maximum loads).

The FHWA fonts used by the Ministry ofTransportation Ontario (MTO) for standard signs anddirectional guide signs are FHWA 2001 CanadianEdition Series C, D, E, and E(m), and less often,Series B or Series F. FHWA Series E(m) is thegenerally preferred font for freeway signs. Other lessfrequently used fonts are Helvetica Medium,Helvetica Bold Condensed, Century Bold andCentury Condensed Bold. See Section 2.5.1 fordetails on font use.

For the customized design of the larger directionalguide signs, a standard library of necessary fonts,particularly those developed by the U.S. FederalHighways Administration (FHWA), is stronglyrecommended.

These FHWA fonts are commercially available, insome cases from the manufacturers of sign-cuttingmachines, and otherwise from Digital Graphics Inc.,tel: (905) 846-8667. Table 2.9 (Sources for TrafficSign Fonts) provides contact information forobtaining fonts used in sign design. AdobeIllustrator has a number of fonts available, some ofwhich may be suitable for traffic sign design, andsome of which are not.

5.1.4 Sign Parts Library

The Master Sign Library also contains the SignParts Library, necessary for the design ofcustomized standard signs, especially thedirectional guide signs, and custom signs. The



contents of the Sign Parts Library need to be usedtogether with the rules for sign design and layout,which are outlined in Section 2.14, and definehow the sign parts are to be used in sign design.

The Sign Parts Library contains the following:

• Arrows• Types of arrows• Dimensions• Patterns

• Crowns, Shields• Symbols

5.1.5 Sign Blanks

MTO has developed a catalogue of standard signblanks. The detailed drawings of standard signblanks for metal signs in the Master Sign Libraryshow the dimensions of the sign as well as thelocation of the mounting holes. In some cases, agiven sign blank may be used with more than onesubstrate material. Table 5.1 lists the MTO standardsign blanks included in the Master Sign Library.



B-6a 100 x 350 Aluminum

B-6b 100 x 375 Aluminum

B-6c 125 x 125 Metal

B-6d 250 x 250 Aluminum

B-6e 300 x 300 Metal

B-6f 150 x 300 Metal

B-6g 150 x 200 Aluminum

B-6h 250 x 450 Aluminum

B-6i 130 x 200 Metal

B-6j 150 x 450 Metal

B-6k 150 x 600 Metal

B-6l 175 x 375 Metal

B-6m 230 x 250 Metal

B-7 300 x 450 Metal

B-7a 300 x 750 Metal

B-8 300 x 900 Metal

B-8a 300 x 900 Plywood

B-8b 300 x 1200 Plywood

B-8c 300 x 1500 Plywood

B-8d 450 x 1200 Plywood

B-8e 450 x 1500 Plywood

B-8f 450 x 1800 Plywood

B-8g 450 x 900 Plywood

B-9 200 x 900 Plastic

B-9a 200 x 900 Metal Mileage Marker

B-9b 200 x 750 Metal

B-10 450 x 450 Metal County/Secondary;Detour Marker

MTO Size Material* CommentBlank (mm x mm)#


B-11 450 x 450 Metal

B-11a 450 x 450 Aluminum STOP/SLOW Paddle

B-12 450 x 750 Steel

B-13 450 x 900 Steel

B-15 450 x 600 Metal

B-17 610 x 610 Metal For Portable signs(size now obsolescent)

B-18 600 x 600 Metal

B-20 600 x 900 Steel


B-20b 600 x 1200 Steel

B-21 457 x 727 Metal Shield

B-22 750 x 900 Steel

B-23 750 x 750 Steel Octagon

B-23a 750 x 750 Steel

B-23b 600 x 600 Steel Octagon

B-23c 900 x 900 Steel Circle

B-24 800 x 800 Steel Pentagon

B-24a 600 x 600 Plywood Pentagon

B-25 200 x 450 Metal

B-25a 200 x 600 Steel

B-25b 300 x 600 Steel

B-25c 225 x 450 Steel

B-26 900 x 900 Steel Triangle (YIELD)

B-26a 750 x 750 Steel Triangle (YIELD)

B-27 900 x 900 Steel

B-28a 900 x 1050 Metal


Table 5.1 – MTO Standard Sign Blanks





Table 5.1 – MTO Standard Sign Blanks (cont’d)

* Where stated as “Metal,” the material may be either Steel or Aluminum.


B-29 900 x 1200 Plywood

B-30 1200 x 1200 Plywood





B-31e 200 x 1800 Plywood

B-31f 200 x 2100 Plywood

B-31g 200 x 2400 Plywood

B-32 250 x 1200 Plywood



B-33 600 x 1500 Plywood

B-34 600 x 1800 Plywood



B-35 750 x 1500 Plywood





B-36 750 x 1800 Plywood


B-37 900 x 1500 Plywood


B-38 900 x 1800 Plywood

B-39 900 x 2100 Plywood

B-40 750 x 900 Plywood Plaque

B-40a 750 x 1500 Plywood Plaque

B-40b 900 x 900 Plywood Plaque

B-40c 900 x 1500 Plywood Plaque

B-42 1200 x 1500 Plywood

B-43 1200 x 1800 Plywood

B-44 1200 x 2100 Plywood

B-45 1200 x 2400 Plywood



B-49 450 x 2100 Plywood

B-50 450 x 2400 Plywood

B-52 600 x 750 Metal

B-54 900 x 2400 Plywood

B-55 1500 x 2400 Plywood

B-57 600 x 1200 Plywood

B-59 450 x 900 Aluminum

B-60 200 x 600 Aluminum Mileage marker;replaced by B-09a

B-61 1200 x 1200 Plywood Octagon

B-63 800 x 1800 Plywood


B-64 300 x 2400 Plywood



5.1.6 CD-ROM Contents

The CD-ROM, included as part of Book 2, isorganized as follows:

1. Read Me (Book 2, Section 5)

2. Adobe® Acrobat® Reader(Available at www.adobe.com)

3. Master Sign Library(Adobe® Illustrator® (.ai) files)

3.1 Sign Blanks (dimensions & drawingsof metal sign blanks)

Sign Blank List

Sign Blank Patterns

3.2 Sign Parts Library

Arrows

Crowns, Shields

Symbols

3.3 Sign Patterns

3.3.1 Book 5 – Regulatory Signs

Ra Signs (each sign class isorganized as shown for Ra signs,with signpattern templates andassociated cut images)

Bilingual Signs (separate folder)

French Signs (separate folder)

English/universal Signs (listedalphanumerically)

Rb Signs

Rc Signs

3.3.2 Book 6 – Warning Signs

Wa Signs

Wb Signs

Wc Signs

3.3.3 Book 7 – Temporary ConditionsSigns

TC Signs

3.3.4 Book 8 – Directional GuideSigns and Markers

Gd Signs

Gf Signs

Gh Signs

GI Signs

Gor Signs

Gr Signs

Grr Signs

Gs Signs

Markers

Mf Markers

Mh Markers

3.3.5 Book 9 – Logo Signs

L Signs

3.3.6 Book 9 – TODS Signs

T Signs

4. Master Sign Library(same breakdown as Section 3)(Adobe® Acrobat® (.pdf) files)



5.2 Use of the Master Sign Library

This section describes the use of the MSL, that is,how to apply the information on the Sign PatternTemplates and the cut images for the purpose ofsign design (where applicable) and sign fabrication.

Because of the variety of available sign cutters andassociated software, this description mustnecessarily be somewhat general.

5.2.1 Standard Signs

For standard signs (regulatory, warning, andtemporary conditions signs), the cut imagesprovided on the Sign Pattern Templates (SPTs) maybe used directly for sign fabrication, after scalingup to full size. The cut images are in .ai format at1/10 scale, and can be scaled up to create full-sizesigns.

In some cases, such as where a sign legend is ofonly one colour, on a background of a differentcolour, the complete sign legend may be cut as anintegral unit. Alternately, individual parts of the signlegend may be cut separately, using theappropriate part(s) of the cut image, andassembled on the background sheeting. Thisalternate approach is also commonly used wherethe sign has multiple colours. Sign borders (innerborders, or outer borders where there is no innerborder) can be cut as part of the complete signlegend, or they can be cut separately and appliedto the sign face.

The cut images of all or part of a sign legend,when scaled up to full size, may also be used tocreate a screen for screen printing of signs. Thesecut images are sent to the cutter for cutting, andthe process is the same, whether a screen is beingcut, or vinyl or reflective sheeting is being cut.

The cut images are imported into the sign cuttersoftware, in a manner appropriate to therequirements of that software, and the cutting isdone by the cutter automatically.

The signs are fabricated as outlined in Section 4 ofBook 2.

5.2.2 Customized Standard Signs

For customized standard signs (directional (guide)and information signs, TODS and logo signs), thescale images provided on the SPTs cannot be useddirectly for sign fabrication. These scale imageslook like cut images but they are not cut images,because the sign legend has to be customized tofit the specific site sign requirements. The scaleimages are in .ai format at 1/10 scale, and they areincluded in the MSL to provide a convenientstarting point for design of the sign. (The imageshown on the SPT itself is not to scale, but isshown at whatever scale is necessary to fill theavailable space on the SPT. Hence, it is not aconvenient starting point for sign design.)

The sign may be designed either with AdobeIllustrator or with the software for the sign cutter.Depending on the specifics of the sign cuttingsoftware, one of these design tools may be moreconvenient than the other.

Once the customized standard sign has beendesigned, all or part(s) of the scaled design (thespecific sign cut image) may be plotted by the signcutter to create the parts required to fabricate thesign.

The signs are fabricated as outlined in Section 4 ofBook 2.



Index

AAmerican Society for Testing and Materials (ASTM),

2.4, 2.9.1, 2.14.2, Table 2.15, Table 3.1 note, 3.1.2,Table 3.2, 3.3.2, Table 3.4

Arrows, 1.1, 2.6.1, Table 2.2, 2.14.2, Table 2.11, 5.1.4

Diagrammatic, 2.14.2, 2.14.3

Downward, 2.14.2

Freeway Advance, 2.14.2

ASTM, See American Society for Testing and Materials

BBenefit/Cost Considerations, 3.2.2

Bilingual Signs, 1.1, 2.12

Sign Design Process, 2.15.1

Sign Patterns, 1.5, 5.1.6

Blank Number, See Sign Blank Number

Bond, 3, 4

Borders, Sign, See Sign Borders

CCanadian General Standards Board, 2.4, 2.9.1, 3.1.2

Candela, 2.9.1, 3.1.2, Table 3.2, 3.2.1, Table 3.3

CGSB, See Canadian General Standards Board

Clearview font, 2.5.1, 2.7.5

Colour, See Sign Colour Specifications

Comprehension, 2.3, 2.6, 2.6.2

Conspicuity, 2.3, 3.2.2

Construction and Maintenance Signs, See TemporaryConditions Signs

Contrast, 2.10

Contrast Ratio, 2.10

Cost Effectiveness, 3.2.2

Crown(s), 1.1, 2.6.1, 2.14.2, 5.1.4

Customized Standard Signs, 2.2, 5.1.2

Sign Design Rules, 2.14.2

Use of MSL, 5.2.2

Cut Image, 1.2, 5.1.2

DDecision Time, 2.7, 2.7.2, 2.7.4, 2.7.7

Design, Signs, See Sign Design Principles; Sign DesignRules; Sign Design Process

Development, New Signs, See Non-standard Signs

Diagrammatic Sign(s), 2.14.3

Diamond Grade Material, See Sign Materials

Dimensioning, See Sign Dimensioning

Directional Guide Sign(s), 1.1, 2.7, 5.1.1


Drawings, Sign, See Sign Pattern Template; MasterSign Library

Driver

Comprehension Testing, 2.13.1

Confusion, 2.6

Error, 2.3

Expectation, 2.3

Information Load, 2.3

Limitations, 2.3

Manoeuvres, 2.3

Requirements, 2.3

Response, 2.3

EEngineering Grade Sheeting, 3.1.1, Table 3.1, 3.1.2

Entrance Angle, 3.1.2

FFabrication, See Sign Fabrication

Federal Highway Administration, 2.5.1, Table 3.1 note,Table 3.4, 5.1.3

FHWA, See Federal Highway Administration

FHWA fonts, 2.5.1, 5.1, 5.1.3

Fluorescence, 3.1.1



Fluorescent Sheeting, 3.1.1

Fonts, 2.5.1, 2.7.5, 5.1, 5.1.3

Sources, 2.14.2, Table 2.9, 5.1.3

French Language Services Office (MTO), 1.5

French-language Signs, 1.1

Sign Design Process, 2.15.1

Sign Patterns, 1.5, 5.1.6

GGround-mounted Sign(s), 2.2


Guide Sign(s), 1.1, 2.7, 5.1.1


HHigh Intensity Sheeting, 3.1.1, Table 3.1, 3.1.2

High Reflectivity Micro-prismatic Sheeting, 3.1.1,Table 3.1, 3.1.2

Highway Traffic Act (HTA), 5.1.2

Horizontal Sign Offset, 3.1.2

Human Factors, 2

IIllumination, Sign, See Sign Illumination

Interdictory Symbol(s), 2.6.2

Interline Spacing, See Sign Design Principles; SignDesign Rules

KKing’s Highway Guide Signing Policy Manual

(KHGSPM), 1.1, 2.14

LLegibility, 2.3, 2.5.2, 2.6, 3.2.2

Distance, 2.3, 2.5.2, 2.6, 2.7.7

Distance, Required, 2.7, 2.7.4, 2.7.7

Symbols, 2.7.6

Letter Height, 2.5.2, 2.7, 2.7.4

Freeway Sign Letter Heights, 2.14.2, Table 2.7

Metric to Imperial Correlation, 2.14.2

Minimum, 2.7, 2.7.4, 2.7.7

Non-freeway Sign Letter Heights, 2.14.2, Table 2.8

Line Spacing, See Sign Design Principles; Sign DesignRules

Logos, 2.6.3

Logo Services Signing, 5.1.1


MManoeuvre Time, 2.7, 2.7.1, 2.7.3, Table 2.3, 2.7.4,

2.7.7

Manoeuvre Types, 2.7.3

Manufacturers’ Recommendations and Specifications,3.1, 3.1.3, 4, 4.1.3, 4.1.4, 4.2

Markers, Route, 1.1, 2.6.1, 2.14.2, 5.1.1, 5.1.4

Master Sign Library (MSL), 5

CD-ROM containing MSL, 5.1.6, inside back coversleeve

Contents, 5.1.6

Description, 5

Electronic Standards, 5.1.3

Elements, 5.1

Sign Blanks, 5.1.5

Sign Classes, 5.1.1

Sign Parts Library, 1.1, 2.6.1, 5.1, 5.1.4

Sign Pattern(s), 2.1, 5.1, 5.1.3

Standard Signs, 2.14.1

Sign Pattern Template, 5.1.2

Sign Shapes and Colours, 2.4

Use of the MSL, 5.2

Customized Standard Signs, 5.2.2


Material Safety Data Sheet (MSDS), See WHMIS

Materials, See Sign Materials

Metrication, 1.4

Ministry of Labour, Ontario, 4

Ministry of Transportation Ontario (MTO),Foreword, 1.1



Driver Licensing, 2.3

French Language Services Office, 1.5

Sign Approval, 2.1

Traffic Office, Foreword

MOL, See Ministry of Labour, Ontario

MTO, See Ministry of Transportation Ontario

NNegative Contrast Signs, 2.10.2, 3.1.3

Non-standard Signs, 2.2, 5.1.2

OObservation Angle, 3.1.2

Occupational Health and Safety Act, 4

Ontario Provincial Standard Specifications (OPSS),3.3.2, Table 3.4, Table 3.5, 4.1.1, 4.1.2, 4.1.3

Ontario Traffic Manual (OTM)

Book 1, 1.1, 2.11, 2.12, 2.13

Book 1b, 1.1, 2

Book 3, 1.1, 3

Book 4, 1.1

Book 5, 1.1, 1.2, 2.2, 2.11, 5.1

Book 6, 1.1, 1.2, 2.2, 2.11, 5.1

Book 7, 1.1, 1.2, 2.2, 2.11, 5.1

Book 8, 1.1, 2.11, 5.1

Book 9, 2.7, 2.11, 5.1

Book 10, 2.7

Committee, Foreword, 2.13

Purpose, Foreword

Revisions, 1.3, 2.11

Target Audience, Foreword

Updating, Foreword

Out-of-view Time, 2.7.1, 2.7.4

Overhead Sign(s), 2.2, 3.1.1


PPerception-reaction Time, See Decision Time.

Permissive Symbol(s), 2.6.2

Positive Contrast Signs, 2.10.1, 3.1.3

QQueen Elizabeth Way (QEW), 2.14.2

RReading Time, 2.7, 2.7.1, 2.7.4, 2.7.7

Reflectance, 2.10.1

Reflectivity, 3.2.2

Reflectorization, 2.4, 2.9

Regulations, 5.1.2

Regulatory Signs, 2.2, 2.7, 5.1.1

Retroreflective Material, 2.4, 2.9.1, 3.1.1, Table 3.1

Engineering Grade, Type I, 2.9.1, Table 3.1, 3.1.1,3.2.1, Table 3.3

High-intensity, Type III or IV, 2.9.1, Table 3.1, 3.1.1,3.2.1, Table 3.3

High-reflectivity micro-prismatic, Type VII, VIII, or IX,2.9.1, Table 3.1, 3.1.1, 3.2.1, Table 3.3, 3.2.2

Retroreflectivity, Coefficient of (R), 2.9.1, 3.1.1, 3.1.2,Table 3.2, 3.2.1, Table 3.3

Route Marker, See Marker

SShields, 2.14.2, 5.1.4

Sign Blank, 1.1

Number(s), 5.1.5, Table 5.1, CD-ROM

Patterns, 1.1, 5.1.5, Table 5.1, CD-ROM

Sign Borders, 2.8.3, 2.14.2, Table 2.12, Table 2.13,Table 2.14

Sign Colour Specifications, 2.14.2, 3.1.2

Sign Corners, 2.14.2, Table 2.12, Table 2.13, Table2.14

Sign Design Elements and Arrangement, 2.8

Sign Design Guidelines, 2

Sign Design Principles, 2.1-2.13

Arrow Type and Size, 2.6.1

Approaches to Sign Design, 2.2



Bilingual Sign Design, 2.12

Calculating Letter Height and Symbol Size, 2.7

Decision Time, 2.7.2

Example, 2.7.7

Manoeuvre Time, 2.7.3, Table 2.3

Minimum Letter Height, 2.7.5, Table 2.4

Reading Time, 2.7.1

Required Legibility Distance, 2.7.4

Symbol Legibility, 2.7.6

Contrast, 2.10

Driver Requirements, 2.3

Horizontal Reduction, 2.5.4

Interdictory and Permissive Symbols, 2.6.2

Letter Height, 2.5.2, 2.7.4

Line Spacing, 2.8.2, 2.14.2

Logo Design, 2.6.3

Process for Assessing and RevisingSign Designs, 2.13


Reflectorization and Illumination, 2.9

Illumination, 2.9.2

Retroreflective Sheeting, 2.9.1

Selecting the Sign Size, 2.11

Sign Design Elements and Arrangement, 2.8

Border Space, 2.8.3

Line Spacing, 2.8.2

Message Length, 2.8.1

Sign Fonts, 2.5.1, Figure 2.1, 2.7.5, 5.1.3

Shape and Colour Codes, 2.4, Table 2.1

Standardization of Design, 2.1

Symbolic Legends, 2.6

Text Legends, 2.5

Upper/Mixed Case, 2.5.3, 2.8.2

Sign Design Process (Procedures), 2.15

Application of Sign Design Process (Examples),2.15.2

Sign Design Flowchart and Description, 2.15.1,Flowchart A

Sign Design Rules, 2.14

Customized Standard Signs, 2.14.2

Arrows, 2.14.2

Abbreviations, 2.14.2

Centring and Justification Guidelines, 2.14.2

Colour, 2.14.2

Differences between Overhead and Ground-mounted Signs, 2.14.2

Letter Size: Metric to Imperial Correlation,2.14.2, Table 2.10

Limits on Destination Legends, 2.14.2

Line Spacing, 2.8.2, 2.14.2

Overhead Signs, 2.14.2

Sign Border Sizing and Radii, 2.14.2, Table2.12, Table 2.13, Table 2.14

Size of Guide Signs, 2.14.2

Style of Lettering and Legend Spacing, 2.14.2,Table 2.7, Table 2.8

Symbols, Crowns, Shields, Markers, 2.14.2

Diagrammatic Guide Signs, 2.14.3

Design Rules, 2.14.3

Usage Not Recommended, 2.14.3

Factors affecting Detailed Sign Design, 2.14, Table2.6

Non-standard Signs, 2.14.4


Sign Dimensioning, 1.4

Sign Effectiveness, 2.3

Sign Fabrication, 4

Background Sheeting Application, 4.2

Heat-activated Sheeting, 4.2.2

Pressure-sensitive Sheeting, 4.2.1

Hand (Squeegee) Application, 4.2.1

Hand Squeeze Roll Applicators, 4.2.1

Mechanical Applicators, 4.2.1

Splicing, 4.2.1

Extruded Aluminum Signs, 1.1, 4.1.4

Legend Preparation and Application, 4.4

Direct-applied Copy, 4.4.2

Computer-cut Copy, 4.4.2

Hand-cut Copy or Individually Cut LegendCharacters, 4.4.2

Reverse-cut Transparent Film, 4.4.2



Screen Printing, 4.4.1

Clean-up, 4.4.1

Printing, 4.4.1

Plywood Signs, 1.1

Sign Assembly (Extruded Aluminum Panels), 4.3

Bolt-together Panels and Snap-together Panels,4.3.1

Aluminum Overlay Sheets, 4.3.2

Sign Fabrication Process, 4.6, Flowcharts B.1 toB.9

Standard Metal Signs on Metal Blanks, 1.1

Storage of Partially Completed and CompletedSigns, 4.5

Substrate Preparation, Testing and Storage, 4.1

Extruded Aluminum Panels and Overlay Sheets,4.1.4

Metal blanks, 4.1

Aluminum, 4.1.1

Steel, 4.1.2

Plastic/Fibreglass, 4.1.5

Plywood, 4.1, 4.1.3

Random Testing, 4.1.6

Recycled Materials, 4.1.5

Storage, 4.1.7

Sign Illumination, 2.4, 2.9

Sign Materials, 3, 4

Background, 1.1, 3.1.1, 3.1.2

Handling and Storage, 4

Legend, 1.1, 3.1.1, 3.1.2

Sign Face Materials, 3.1

Overlay Films, 3.1

Screen Printing Ink and Coatings, 3.1, 3.1.3

Sign Sheeting, 3.1.1

Durability and Service Life, 3.2.1, Table 3.3

Non-retroreflective Sheeting, 3.1.1

Performance, 3.2

Retroreflective Sheeting, 3.1.1, 3.1.2

Standards and Specifications, 3.1.2, Table3.2

Type I, 3.1.1, 3.1.2, Table 3.2, Table 3.3

Type III or IV, 3.1.1, 3.1.2, Table 3.2, Table3.3

Type VII, VIII or IX, 3.1.1, 3.1.2, Table 3.2,Table 3.3, 3.2.2

Weathering Requirements, 3.1.2

Substrates, 1.1, 3.3

Standards and Specifications, 3.3.2

Substrate Materials, 3.3.1

Aluminum, 3.3.1

Aluminum Overlay Sheets, 3.3.1

Extruded Aluminum, 3.3.1

Fibreglass, 3.3.1

Fibreglass-plastic, 3.3.1

Plastic, 3.3.1

Plywood, 3.3.1

Recycled Materials, 3.3.1

Steel, 3.3.1

Substrate Preparation, Testing and Storage, 4.1

Sign Numbering System, 1.2, 5.1.2

Previous System, 1.2, Table 1.1

New System, 1.2, Table 1.1, 5.1.2

Sign Parts Library, 1.1, 2.6.1, 2.14.2, 5.1, 5.1.4, MSL,CD-ROM

Sign Patterns, 2.1, 2.14.2, 5.1, MSL, CD-ROM

Sign Pattern Template (SPT), 1.1, 1.2, 2.2, 2.14,2.14.2, MSL, CD-ROM

Sign Shape and Colour Codes, 2.4, Table 2.1

Sign Sheeting, See Sign Materials

Sign Size, 2.11

Maximum, 2.11, 2.14.2

Guide Signs, 2.14.2

Sign Symbol(s), 2.6

Design Rules, 2.14.2

Legibility, 2.7

Sign Parts Library, 5.1.4, MSL, CD-ROM

Sign Testing, 2.6, 2.7.1, 2.13


Sign Tilt Angle, 3.1.2

Stakeholder Advisory Committee (SAC), Foreword



Standard Signs, 1.1, 2.2, 5.1.2


Use of MSL, 5.2.1

Standard Signs, Customized, See CustomizedStandard Signs

Standardization of Sign Design, 2.1

Substrate, See Sign Materials

Symbol, See Sign Symbol(s)

TTab Sign(s), 2.3, 2.14.2

T-bars, 4.3.1

Temporary Conditions Signs, 2.2, 4.1, 5.1.1

Tourism Oriented Destination Signing (TODS), 5.1.1


Tourism Signing, 2.7, 5.1.1

Transportation Association of Canada, 2.1

UUniformity, Foreword, 2.1

University of Toronto Press (UTP), Foreword

VVertical Sign Offset, 3.1.2

WWarning Signs, 2.2, 2.7, 5.1.1

Workplace Hazardous Materials Information System(WHMIS), 4, 4.1.2

Material Safety Data Sheet (MSDS), 4, 4.1.2

ZZ-bars, 4.3.1



Appendix A • Definitions

AAdhesionThe ability of a sign sheeting to adhere (bond strongly)to the substrate to which it is attached. Thespecification indicates the bond strength of theadhesive backing of the sheeting, in terms of minimumweight supported for 5 minutes, without the bondpeeling for more than a specified maximum distance,when tested according to the procedure described inthe specification. The minimum weight that must besupported varies by class of adhesive.

ArrowA symbol indicating the direction of movement that adriver may or must make, as the case may be, or thedirection of a destination.

ASTMAmerican Society for Testing and Materials.

At-grade IntersectionAn intersection of two roadways where there is novertical separation between the two roadways at theirpoint of intersection.

BBilingual SignA sign which has its message (legend) in both Englishand French.

Blank NumberSee Sign Blank Number.

BondAdhesive quality of a coating or sheeting to aSubstrate.

BrightnessA term that refers to human perception of Luminance.Whereas luminance is a photometrically measuredquantity, brightness describes how intense a lightsource or lighted surface appears to the human eye.

CCandelaThe basic SI unit of luminous intensity.

CGSBCanadian General Standards Board.

ColourfastnessThe ability of Sign Sheeting to retain its original coloursafter testing or after use in the field.

Commercial SignA sign falling into one of the following classes:

(1) field advertising;

(2) third-party signs; or

(3) other commercial signs, on the highway right-of-way, for which a fee may be charged.

ComprehensionThe ability of drivers to understand the meaning of asign message, including any symbols or abbreviations.

ConspicuityThe ability of a Traffic Control Device to attract orcommand attention, given the visual setting in whichit is placed.



Construction and Maintenance SignsA group of Regulatory and Warning Signs used for theprotection of public traffic and workers in the vicinity ofa work area located on or near the roadway.

Continuous Wide MedianOn a divided highway, a median that has a continuouswidth of 10 m or more. See also Divided Highway.

ContrastContrast refers to differences in colour or in brightnesswhich allow a target, such as a sign message orsymbol, to be seen against the sign background.

For light-emitting dynamic message signs, the samerelationships apply, except that reflectance is replacedby emitted light intensity for both legend andbackground.

Cost-effectivenessThe relationship between a measure’s benefit over itsservice life and the total costs it incurs over its servicelife, often expressed as a ratio.

CrownA particular type of sign symbol, in the shape of acrown, used for King’s Highway numbers, either byitself or as part of a Directional Guide Sign.

CurveA horizontal or vertical deviation in the roadway. Ahorizontal curve appears as a bend in the roadway,requiring drivers to turn the steering wheel. A verticalcurve appears either as a “crest” or a “sag” to providefor a change in gradient on the profile of the roadway.

Curve SignA Warning Sign used to inform drivers of an upcomingchange in roadway alignment. In some cases, areduction in speed is recommended.

Customized Standard SignA sign which is in the Master Sign Library, but whichneeds to be adjusted to accommodate a specific localsign message. Most customized standard signs areDirectional Guide Signs and need to be designedaccording to the sign design rules and sign designprocess outlined in Book 2, Sections 2.14 and 2.15.

Cut ImageThe accurate, scaled template of a standard regulatory,warning, or temporary conditions sign that may beused directly for sign manufacture, supplied in theMSL.

DDaytime ColourDaytime Sign Sheeting colour as defined by daytimecolour specification limits using four pairs ofchromaticity coordinates to determine the acceptablecolour in terms of the CIE 1931 Standard ColorimetricSystem.

Decision TimeThe time required to make a decision and initiate amanoeuvre, if required, after reading or encountering aTraffic Control Device. Also called perception-reactiontime.

DelineatorsSmall, Retroreflective devices erected in a seriesadjacent to the edge of a travelled portion of theroadway for the purpose of providing positive driverguidance.



Design SpeedA speed selected for purposes of design andcorrelation of those features of a highway, such ascurvature, superelevation, and sight distance, uponwhich the safe operation of vehicles is dependent.

DetourA diversion from the usual travelled roadway; either acrossover from one multi-lane roadway to another(within the highway right-of-way), or a Route Detour.

Detour MarkerA sign used to identify a Route Detour for detour routecontinuity, to assist driver navigation.

Device (Traffic Control)See Traffic Control Device.

Diagrammatic SignA sign used primarily on freeways, which usesgraphics to display the approximate geometry ofthe interchange or intersection, including laneconfiguration, along with essential directionalinformation.

Diamond Grade MaterialA non-metallized, high reflectivity micro-prismatic signsheeting material (ASTM Type VII, VIII, or IX). Thematerial may be fluorescent or non-fluorescent.

Directional Guide SignA broad class of signs providing route-finding oroperational guidance to road users, including directionto specific destinations.

Diversion RouteA route where the driver is required to departcompletely from the normal route and is directed touse an alternate route.

Divided HighwayA multi-lane highway consisting of roadways foropposing traffic which are separated by an unpavedarea or other physical barrier, including a curbedisland. See also Continuous Wide Median.

DOTU.S. Department of Transportation.

DriverA person who operates a vehicle on a highway.

Driver ResponseThe driver action taken as a result of reading a trafficsign or encountering another traffic control device.

EEighty-fifth (85th) Percentile SpeedThe speed at, or below which, 85% of motorists aretravelling.

Engineering Grade MaterialA retroreflective sign sheeting material meeting ASTMSpecification D 4956-01a for Type I material or CGSBSpecification 62-GP-11M for Reflectivity Level IImaterial.

Entrance AngleThe horizontal angle between the headlight beam anda line perpendicular to the sign. For computation of theentrance angle, the headlight beam is usuallyconsidered to emanate from a point midway betweenthe two headlights.

ExpectancyUsed in traffic engineering to describe a driver’santicipation of upcoming road design and trafficcontrol conditions. Driver expectancy is usuallyaffected by previous experience and the consistencyand continuity of traffic control devices encountered.



ExpresswayA divided arterial highway for through traffic with fullor partial control of access and generally with GradeSeparations at major intersections.

FFabricationThe construction and/or assembly of a traffic controldevice and/or its supports. See also Sign Fabrication.

FHWAU.S. Federal Highway Administration.

FHWA FontsA series of fonts used in sign design.

FluorescenceThe emission of light produced by certain substanceswhen excited by an ultraviolet (UV) energy source. Thisemission ceases when the UV source is removed.

Fluorescent Orange and Yellow-GreenFluorescent sign sheeting colours designed for highconspicuity in daytime. Fluorescent sign sheeting maybe non-reflective (daytime use only) or reflective(daytime and nighttime use).

FontA set of letters, numbers, and symbols of a unifieddesign and given size, and designated by name.

FreewayA multi-lane Divided Highway with continuous dividingmedian, full control of access and interchanges inplace of At-grade Intersections, and a posted speed of90 km/h or greater.

French Language (French) SignsA sign whose text message is in the Frenchlanguage only.

GGrade CrossingA railroad crossing a highway at the same elevation (novertical separation).

Grade SeparationThe vertical separation of two or more intersectingroadways or a roadway and another transportationmode, e.g., railroad, thus permitting traffic on all roadsto cross traffic on all other roads without interference.

Ground-mounted SignA sign mounted beside the Roadway rather thanabove it.

GuidelineA recommended practice, method or value for aspecific design feature or operating practice.

Guide SignA Traffic Sign used to direct traffic along a routetowards a destination.

HHigh Intensity MaterialA retroreflective sign sheeting material meeting ASTMSpecification D4956-01a for Type III or IV, or CGSBSpecification 62-GP-11M for Reflectivity Level Imaterial.

High Occupancy Vehicle (HOV)A vehicle that carries a defined minimum number ofpersons (typically two or three).

HighwayA general term denoting a public way for purposes ofvehicular and pedestrian travel, including the entirearea within the Right-of-way. This includes King’sHighways, regional and county roads, rural roads,municipal roads, and streets.



Highway Traffic Act (HTA)The Ontario Highway Traffic Act.

Horizontal Sign OffsetThe horizontal distance between the edge of thepavement and the nearer edge of a ground-mountedtraffic sign.

HOVHigh Occupancy Vehicle.

HTAHighway Traffic Act (Ontario).

Human FactorsThe consideration of human physical, perceptual andmental limitations in engineering design, so as tooptimize the relationship between people and things.The objective is to reduce error and increase usercomfort.

IInformation LoadThe amount of information presented to a driver by aSign or other Traffic Control Device, which is a factor indetermining the amount of time drivers require to read,comprehend, and act upon the message.

InterchangeA system of interconnecting roadways in conjunctionwith one or more grade separations, providing for theinterchange of traffic between two or more roadwayson different levels.

Interdictory SymbolAn annular (circular) red band with a diagonal redstroke at 45 degrees, or as close to 45 degrees aspractical, signifying that whatever is depicted withinthe symbol is prohibited.

Interline SpacingThe vertical space between the bottom of onemessage line on a sign and the top of the messageline beneath it. Also called line spacing or ‘leading’(pronounced ‘ledding’).

IntersectionThe area embraced by the prolongation of lateral curblines or, if none, of the rights-of-way of two or morehighways that join one another at an angle, whether ornot one highway crosses the other.

Intersection ApproachThat part of an Intersection Leg used by trafficapproaching the intersection.

Intersection ChannelizationRaised or painted islands at an intersection that preventspecific movement(s) from being made or providebetter definition of large uncontrolled areas ofpavement.

Intersection LegThat part of any one of the roadways radiating from theintersection which is close to the intersection butoutside the area of the intersection proper.

ITEInstitute of Transportation Engineers.

JJunctionSee Intersection.

JurisdictionA legal or other authority with responsibility andcontrol for specific actions within a defined area.



KKHGSPMKing’s Highway Guide Signing Policy Manual (Ontario).

Kilometre (km)A measure of distance equal to 1,000 m (0.621 miles).

King’s HighwayA highway, including secondary and tertiary roadsdesignated under the Public Transportation andHighway Improvement Act.

King’s Highway Guide Signing Policy Manual(KHGSPM)The Ministry of Transportation Ontario manual forguide signing on provincial highways. It is beingsuperseded by OTM Book 8 (Directional andInformation Signs) and Book 9 (Tourism andCommercial Signs).

kmAbbreviation for kilometre.

LLaneA defined width of road intended to accommodate asingle line of moving vehicles.

Lane Designation SignAn Overhead or Ground-mounted Sign, erected at or inadvance of an intersection, or over a lane or lanes, toregulate traffic on an approach by assigning certaintraffic movements to specific lanes or a reserved lane.These signs should not be confused with Turn ControlSigns.

Lane Use SignSee Lane Designation Sign.

Left-turn LaneA lane reserved for left-turning vehicles and sodesignated by Pavement Markings and/or LaneDestination Signs.

Legal AuthorityThe authority provided by legislation and regulations,to a jurisdiction or enforcement body for the actionsit takes.

LegendThe complete message on a sign, which may includetext, symbols, arrows, markers, shields, crowns, anddiagrams.

LegibilitySign legibility is governed by the distance at which thesign becomes legible and the duration for which itremains legible. Legibility depends on Font, character,word and Interline Spacing, Contrast ratio, and clarityof symbols.

Legibility DistanceThe distance at which a sign can be read by a givendriver under prevailing conditions.

Legibility Distance, RequiredThe distance at which a sign must be legible, based onthe travel speed and the sum of Reading Time,Decision (perception-reaction) Time, and ManoeuvreTime.

Line SpacingSee Interline Spacing.

Logo Services SigningLogo-based signing located on freeways, onapproaches to interchanges, for specific food, fuel andaccommodation (lodging) services and establishments.



LuminanceReflective light; the luminous flux in a light ray,emanating from a surface or falling on a surface, in agiven direction, per unit of projected area of thesurface as viewed from that direction, per unit of solidangle.

MmAbbreviation for Metre.

MaintenanceThe upkeep of highways, traffic control devices, othertransportation facilities, property and/or equipment.

Manoeuvre TimeThe time to complete any required manoeuvre beforereaching a sign, other traffic control device, or decisionpoint.

MarkerA particular type of sign symbol used for regional,county, or municipal route numbers, either by itself oras part of a Directional Guide Sign.

Master Sign Library (MSL)The electronic library of all signs in the OTM, includingscaled sign pattern templates and cut images for thefabrication of standard signs. The MSL is stored on aCD-ROM as part of Book 2, and is made up of:

(1) Sign Blank list and patterns;

(2) Sign Parts Library; and

(3) Sign Patterns.

Material Safety Data Sheet (MSDS)A sheet for each specific product identified under theWorkplace Hazardous Materials Information System(WHMIS) which describes the composition of theproduct. It also gives details on the safe handling andstorage of the product as well as personal protectivesafety equipment that is required when using theproduct, and other protective devices such as fumehoods and breathing apparatus. Handling, storage anduse of each specific product must conform to theseregulations.

Maximum SpeedThe maximum speed drivers are permitted to travel.The maximum speed is imposed by the HighwayTraffic Act, or municipal by-laws. See also NormalPosted Regulatory Speed.

MayIndicates a permissive condition. No requirement fordesign or application is intended. However, mandatoryrequirements apply to some specific options if andwhen they are selected.

MedianThat portion of a Divided Highway separating thetravelled ways for traffic in opposite directions.

Median IslandA zone or physical island constructed in the centre of aroadway to separate opposing directions of traffic.

Median StripAn expanse of hard surface material separatingopposing lanes on a highway. The hard surface is flushor nearly flush with the adjacent lanes.

Metre (m)A metric unit and the base SI unit of linear measure,equal to about 39.4 inches.



MinistryUnless otherwise specified, the Ministry ofTransportation Ontario (MTO). Where so specified, theMinistry means the Ontario Ministry of Labour (MOL).

MOLThe Ontario Ministry of Labour.

MotoristSee Driver.

MSDSMaterial Safety Data Sheet.

MSLMaster Sign Library

MTOThe Ministry of Transportation Ontario.

Multi-lane HighwayA roadway with two or more travelled lanes carryingtraffic in each direction.

MustIndicates a mandatory condition. Where certainrequirements in the design or application of the deviceare described with the “must” stipulation, it ismandatory that these requirements be met when aninstallation is made.

MUTCDThe Manual of Uniform Traffic Control Devices forOntario, 1995.

MUTCDCThe Manual of Uniform Traffic Control Devices forCanada, 1997, and its subsequent updates.

MUTCD-USThe U.S. Manual on Uniform Traffic Control Devices,2003 Edition.

NNon-standard SignA sign which is not included in the MSL, and whichneeds to be designed by the user. Some examples ofthese are special warning signs. Note however, thatnon-standard signs still need to follow basic rules ofdesign.

No ParkingSee Parking and Parking Restriction.

Normal Posted Regulatory SpeedThe regulatory maximum speed posted on a highwayunder normal conditions, that is, when no constructionzone or work activity is present.

No StandingThe prohibition of the halting of a vehicle whetheroccupied or not, except for the purpose of and whileactually engaged in the receiving or discharging ofpassengers.

No StoppingThe prohibition of the halting of a vehicle, eventemporarily, whether occupied or not, except wherenecessary to avoid conflict with other vehicles, or incompliance with the directions of a police officer orTraffic Control Signal.

OObservation AngleThe vertical angle formed by light travelling from avehicle’s headlights and reflected off the sign back tothe driver’s eye.

Occupational Health and Safety Act (OHSA)The Ontario Occupational Health and Safety Act andRegulations, of the Ontario Ministry of Labour (MOL).



Official SignAny sign approved by the Ministry of TransportationOntario (MTO).

OHSAOccupational Health and Safety Act.

Older DriverA driver aged 55 years or older.

Ontario Provincial Standard Specifications (OPSS)A compilation of standard specifications for materialsand products used in road construction andmaintenance, compiled by the Ministry ofTransportation Ontario together with otherstakeholders.

Ontario Traffic Manual (OTM)A comprehensive user manual for traffic practitioners,addressing the needs of all Ontario road authorities,superseding the Manual of Uniform Traffic ControlDevices (MUTCD) and the MTO King’s Highway GuideSigning Policy Manual (KHGSPM). The OTM has beenin development since 1997, and is issued as individuallybound books.

Operating SpeedThe speed at which the majority of vehicles aretravelling, typically the 85th Percentile, regardless ofthe speed limit.

OPSSOntario Provincial Standard Specifications.

OTMOntario Traffic Manual.

Out-of-view TimeThe period of time, when approaching a sign, whenthe sign is very close, is seen on an angle, andbecomes difficult to read. It is assumed in the OTMthat the sign is not read for the last 1/2 second, theout-of-view time.

Overhead SignA Traffic Sign mounted above the Roadway, usuallywith 4.5 m to 5.3 m of vertical clearance andpreferably mounted over the lane or lanes to which thesign applies.

OverpassA Grade Separation where the travel way in questionpasses over the other travel way.

Oversize SignA Traffic Sign with greater proportional dimensionsthan the minimum dimensions specified in the OTM.Such signs are generally required on higher speedhighways, or on other highways in special cases.

PParkingThe stationary storage or leaving of a vehicleunoccupied or unattended.

Parking Control SignA sign which identifies the time of day and days ofweek parking, stopping or standing restrictions are inplace on the section of road adjacent to the sign.

Parking RestrictionA limitation which prohibits vehicles from being parkedin specific locations, at specific times, or for specifictype of vehicle. Most often used to control on-streetparking.

Parking (and Stopping) SignsA Traffic Sign of the regulatory type which informsdrivers of the parking and stopping regulations in effecton facilities where such signs are erected.



Pedestrian Crossover (PXO)Any portion of a Roadway, designated by municipal by-law, at an intersection or elsewhere, distinctly indicatedfor pedestrian crossing, by signs on the highway andlines or other markings on the surface of the roadway,as prescribed by the regulation and the HTA, withassociated signs Ra-4, Ra-4t, Ra-10 and Ra-11.

Pedestrian CrosswalkAny portion of the Roadway, at an intersection orelsewhere, distinctly indicated for pedestrian crossingby appropriate pavement markings and/or signs, or bythe projections of the lateral lines of the sidewalk onopposite sides of the road.

Pedestrian SignSee School and Pedestrian Signs.

Perception-reaction TimeSee Decision Time.

PermissiveRefers to areas where a driver is permitted to travel.

Permissive SymbolAn annular (circular) green band used on a sign tosignify that whatever is depicted within the symbol ispermitted.

Positive GuidanceProvision to road users of the information they need toavoid hazards, when and where they need it, in a formthey can best use it. See Book 1c (Positive GuidanceToolkit).

Posted Advisory SpeedThe maximum advisory speed as indicated byappropriate Warning or Temporary Conditions Signs.

Posted Speed ZoneA section of highway upon which the maximum speedis indicated by appropriate Regulatory Signs.

Prescribed SignA sign prescribed by the Highway Traffic Act (HTA),Section 182 (R.S.O. 1990) and its regulations,providing for the the type of sign and its location onthe roadway. The criteria and specifications forapplication, dimensions, location and orientation areprescribed and illustrated under Regulations 615, 608,581, 599 (R.R.O. 1990). Signs erected in accordancewith the Regulations, and pursuant to the HighwayTraffic Act, are enforceable under various provisions ofthe Act. Enforcement is permitted under the particularsection under the authority of which a prescribed signmay be erected to indicate a traffic regulation, or HTASection 182 (R.S.O. 1990), which requires obedienceto prescribed signs.

Provincial HighwayAny public highway under the jurisdiction of theMinistry of Transportation Ontario (MTO). See King’sHighway.

Public RoadwayAny roadway under the jurisdiction of and maintainedby a public authority and open to public travel.

Public WayA sidewalk, street, highway, square, or other openspace to which the public has access, as of right or byinvitation, either express or implied.

PXOPedestrian Crossover.

RRailroad CrossingA location where one or more railroad tracks cross apublic highway, road, street, or a private roadway, andincludes sidewalks and pathways at or associated withthe crossing.



RampAn interconnecting Roadway of a traffic Interchange,or any connection between highways at differentlevels, or between parallel highways, on which vehiclesmay enter or leave a designated roadway.

Reading TimeThe time required to read a sign.

ReflectanceSee Reflectivity.

ReflectivityA measure of the degree to which a surface reflectsincident light. A related term, reflectance, is theamount of light reflected back from a sign, relative tothe amount of light shining on the sign. SeeRetroreflectivity, Coefficient of (R).

ReflectorizationA method of incorporating light-reflective material onthe approach face of a Traffic Sign so that the face willreflect light during the hours of darkness whileretaining the same colours as by day.

RegulationA prescribed rule, supported by legislation, such as anyregulation made under the HTA or OHSA or municipalby-law. Regulations provide the legal basis forenforcement.

Regulatory SignA Traffic Sign advising drivers of an action they shouldor must perform (or not perform) under a given set ofcircumstances. Disregard of a regulatory sign wouldusually constitute an offence.

Reserved LaneA street or highway lane reserved for use by specificclasses of vehicles, either all day, or during specifiedperiods. These classes may include any or all of buses,carpools, taxis or bicycles.

Reserved Lane ControlsAll controls, including Traffic Control Devices andphysical devices, intended to ensure that a ReservedLane functions in accordance with its intendedpurpose.

Response TimeThe time between the occurrence of an event and theaction taken to respond to the event.

RestrictiveRefers to areas where, or times when, a driver is notpermitted to travel, stop, stand, or park.

Retroreflective MaterialA type of material applied in either strips or sheetswhich reflects illumination back to its source.

Retroreflectivity, Coefficient of (R)R indicates the proportion of light reflected back to thedriver from a retroreflective sign surface, in candelasper lux per square metre.

Right-of-way (ROW)(1) Allocation of right of movement to a road user, in

preference over other road users;

(2) The width of the road allowance from theproperty line on one side to the property line onthe opposite side of the roadway.

Right-of-way RuleAlthough these may vary in specific localities, generallya vehicle approaching an uncontrolled intersectionmust yield to a vehicle approaching on the leg to itsright.

Right Turn on Red (RToR)A right-turning movement permitted on a red signalindication after coming to a stop and ensuring that aright turn can be made safely. Allowed by the HTA, butsubject to site-specific local by-laws.



RoadSee Highway.

Road AuthorityThe body (Municipal, Provincial or private) that haslegal jurisdiction over a roadway.

RoadwayThe part of the Highway that is improved, designed orordinarily used for vehicular traffic, but does notinclude the Shoulder, and, where a highway includestwo or more separate roadways, the term “roadway”refers to any one roadway separately and not to all ofthe roadways collectively.

Roadway Alignment SignA Warning or Temporary Conditions Sign used toinform drivers of an upcoming change in roadwayalignment, including turns and Curves.

Route DetourA detour where a driver is required to departcompletely from the normal route and is directed touse an alternate route. The alternative route must besigned using a combination of the appropriate TC-10directional signs. See OTM Book 7.

Route MarkerA Guide Sign bearing a route number which is erectedalong numbered highways.

ROWRight-of-way.

RToRRight turn on red.

Rural AreaAn area outside of the limits of any incorporated orunincorporated city, town, village, or any otherdesignated residential or commercial area.

SSafe SpeedSee Advisory Speed.

School (and Pedestrian) SignsA group of signs, both Regulatory and Warning, usedto control vehicles and protect pedestrians whereverstudents and pedestrians are likely to be present andconflict with vehicles may occur.

School ZoneA section of roadway in the vicinity of a school, with amandatory 40 km/h maximum speed zone, in effect atdesignated times every school day. The HTA alsomakes provision for 60 km/h speed zones on King’sHighways.

Separate RoadwayA physically separated, access controlled, HOV prioritytreatment facility, usually located within the median ofan urban freeway. Separated roadways can be eitherreversible or two-way, single or multi-lane facilities.

ShallMeans the same as “must”.

Shared RoadwayAny roadway upon which a Reserved Lane is notdesignated and which may be legally used by a varietyof vehicle types regardless of whether such facility isspecifically designated. This includes bicycles, buses,taxis, and carpools.



ShieldA particular type of sign symbol used for provincialhighway numbers, either by itself or as part of aDirectional Guide Sign.

ShouldIndicates that an action is advised; recommended butnot mandatory. ‘Should’ is meant to suggest goodpractice but allows that in some situations, for goodreasons, the recommended action cannot or need notbe followed.

ShoulderThe portion of a Highway between the outer edge ofthe roadway and the Curb, or point of intersection ofthe slope lines at the outer edge of the roadway andthe fill, ditch, or median slope. Used to accommodatestopped vehicles, for emergency use, and for lateralsupport.

SidewalkThat portion of a road, adjacent to the travelledroadway, which has been improved for the use ofpedestrians.

SignA Traffic Control Device mounted on a fixed or portablesupport which conveys a specific message by meansof symbols or words, and is officially erected for thepurpose of regulating, warning, or guiding traffic.

Sign AssemblyAny Traffic Sign mounted and erected alone or inconjunction with any combination of associated TabSigns.

Sign BlankThe Substrate for a given size of standard sign.

Sign Blank ListThe list of standard sign blanks and numbers, includedas part of the Master Sign Library.

Sign Blank NumberThe number issued to a given size of standard SignBlank (substrate), for purposes of identification,inventory and fabrication.

Sign Blank PatternA scaled, dimensioned pattern suitable for fabricationof standard metal Sign Blanks. Sign blank patterns areincluded as part of the Master Sign Library.

Sign FabricationThe process of producing a sign including: substratefabrication, preparation, extruded panel assembly,application of background sheeting, and application oflegend, but excludes sign mounting or installation inthe field.

Sign MaterialsThose materials used in signs, including substrate,extruded aluminum panels and hardware, backgroundsheeting, and legend (vinyl, retroreflective sheeting,paint, or ink).

Sign Parts Library (SPL)The library of scaled drawings of sign parts, such asarrows, markers, crowns, shields, and symbols, whichmay be used in the design of signs. The SPL isincluded as part of the Master Sign Library.

Sign PatternThe full-size drawing of an individual sign, showingsufficient detail and dimensional accuracy for signfabrication.

Sign Pattern Template (SPT)The base record of reference in the OTM Master SignLibrary for sign design. The SPT includes: a sign image,sign numbers, sizes, sign blank numbers, colours,minimum reflectivities, fonts, special notes, and scaledtemplates (cut images) for the design of StandardSigns.



Sign SheetingThe Retroreflective Material used on the surface of aSign to provide good daytime and nighttime visibility.

Sign SupportThe physical means of holding a sign in its intendedposition.

Sign SymbolA pictogram, depiction, arrow, silhouette or figure, and/or Interdictory or Permissive Symbol, used to simplifyor represent a word message on a sign.

Specular GlossA measurable characteristic of Retroreflective sheetingwhich, when subjected to light at specific angles, canresult in glare for drivers.

Speed LimitThe maximum vehicular speed allowed within anygiven posted or unposted Speed Zone.

Speed ZoneA specific section of roadway upon which a maximumspeed limit has been imposed. Such zones may beposted or unposted. A construction speed zone mustbe posted.

SPLSign Parts Library.

SPTSign Pattern Template.

StandardA rule, principle, pattern or measure, which practice ortheory has shown to be appropriate for a given set ofconditions, and applicable, as the case may be, toplanning, design, traffic control devices, operations ormaintenance.

Standard SignA sign in the Master Sign Library for which the cutimages may simply be used as is or with very minorchange (e.g., speed limit sign numeral 90 instead of50 as shown). Most regulatory, warning, andtemporary conditions signs (Books 5, 6, and 7respectively) are standard signs.

Standard Sign, CustomizedSee Customized Standard Sign.

StandingThe halting of a vehicle whether occupied or not. Seealso No Standing.

Statutory Speed LimitA maximum speed limit automatically in effect on allroads, unless otherwise signed. The statutory speedlimit applies even where no maximum speed limits aresigned.

StoppingThe halting of a vehicle, even temporarily, whetheroccupied or not. See also No Stopping.

Stopping Sight DistanceThe distance required by a driver of a vehicle, travellingat a given speed, to bring the vehicle to a stop after anobject on the roadway becomes visible. It includes thedistance travelled during the Decision Time and thevehicle braking distance.

StreetAn urban Highway.

SubstrateThe material and surface to which the sign sheeting isapplied.

SymbolSee Sign Symbol.



TTab SignA sign smaller than the primary sign with which it isassociated, and mounted below it. There are two typesof tab signs:

(1) Supplementary Tab Sign – contains additional,related information;

(2) Educational Tab Sign – conveys the meaning ofsymbols during their introductory period.

TACTransportation Association of Canada.

T-BarA metal bar used on the back side of an extrudedaluminum sign, at right angles to the length of the signpanels, for purposes of connection, bracing, andstructural rigidity.

TCTemporary Conditions.

Temporary Conditions (TC)Roadway and traffic control conditions related tonon-permanent construction, maintenance and utilitywork on any highway.

Temporary Conditions SignA Regulatory, Warning, or Guide Sign, intended to beused for Temporary Conditions.

TextThe part of a sign legend consisting of words.

Time of OperationThe time period for which a traffic system is inoperation or during which a prohibition or restriction isin effect.

TODTime of Day.

TODSTourism Oriented Destination Signing.

Tourism Oriented Destination Signing (TODS)A program of tourism signing developed for provincialhighways with Trailblazing continuity on other roads.Some municipalities have developed municipal tourismsigning programs compatible with TODS.

Tourism SigningInformation signing for tourist-related attractions.Tourism signing includes TODS as well as non-TODSsigning for local and municipal attractions.

Traffic Control DeviceAny sign, signal, marking, or device placed upon, overor adjacent to a roadway by a public authority orofficial having jurisdiction, for the purpose ofregulating, warning, guiding or informing road users.

Traffic SignA device (other than Pavement Markings, Delineatorsand Traffic Control Signals) which may be erectedbeside or above a roadway for the purpose ofregulating, warning or guiding traffic.

TrailblazerA small identification sign which provides continuityand assurance for drivers wishing to follow a givenroute or to reach a given destination.

Travel SpeedRate of motion. Ratio of travel distance and travel time.

Travel TimeThe time of travel, including stops and delays exceptthose off the travelled way.



Turn Control SignA Traffic Sign, generally erected at an intersection,indicating by arrows and an Interdictory Symbol themovement or movements traffic on that approach mustnot take. These signs should not be confused withLane Designation Signs.

Turn ProhibitionA regulation prohibiting a straight-through movementor a left or right turn at an intersection.

Turn SignA Warning Sign used to inform drivers of an upcomingchange in roadway alignment. See also Curve Sign.

Two-lane HighwayAn undivided two-way facility having one lane fortraffic moving in each direction.

Two-way Left-turn LaneThe centre lane on some three, five or seven lanesections of undivided highway which is designed tofacilitate left turns from each direction.

UUncontrolled IntersectionAn intersection which does not have Right-of-waycontrol devices on any of the approaches.

UnderpassA grade separation where the travel way in questionpasses under another travel way.

Undivided HighwayA multi-lane highway with no continuous Median, orwith a paved flush dividing strip, or with a Two-wayLeft-turn Lane.

UniformityConsistency in the design, fabrication and applicationof traffic control devices and operations.

Urban AreaAn indefinite area of land used primarily for residential,commercial, and/or industrial purposes, usuallyassociated with a given area size, population, anddensity.

VVVelocity.

VehicleIncludes a motor vehicle, trailer, traction engine, farmtractor, road-building machine, bicycle, and any vehicledrawn, propelled or driven by any kind of power,including muscular power, but does not include amotorized snow vehicle or motorcycle sidecar.

Vehicle EligibilityEligibility of a vehicle to use a reserved lane or parkingspace, based on meeting defined criteria.

Vehicle OccupancyThe number of persons, including the driver andpassenger(s), in a vehicle at a given time. See alsoHigh Occupancy Vehicle (HOV).

Vertical Sign Offset (Vertical Sign Clearance)(1) For ground-mounted signs, the vertical sign

offset is the vertical distance between thebottom of the sign face and the elevation of theedge of the nearest traffic lane or of thesidewalk, as the case may be.

(2) For overhead-mounted signs, the vertical signclearance is the vertical distance between thebottom of the sign face and the elevation ofthe highest point of the pavement surfacebeneath it.



VolumeThe number of vehicles or pedestrians that pass over agiven section of a lane or a roadway or make aparticular movement during a specific time period(such as one hour or 24 hours).

WWarning SignA sign which indicates conditions on or adjacent to ahighway or street that are actually or potentiallyhazardous to traffic operations.

WarrantA criterion or set of criteria by which justification for agiven type of Traffic Control Device or other applicationis determined.

Weathering RequirementsSign material (sign sheeting) specification tests, toverify that sign sheeting is weather resistant and showsno appreciable cracking, scaling, pitting, blistering,edge lifting, or curling, and remains within specifiedlimits for shrinkage and expansion, when testedaccording to the procedure described in thespecification.

WHMISWorkplace Hazardous Materials Information System.See Material Safety Data Sheet (MSDS).

Work ZoneA section of highway or roadway where highway-related construction, maintenance, or utility work takesplace. See Book 7.

YYieldTo cede the right-of-way.

ZZ-BarA metal bar used on the back side of an extrudedaluminum sign, at right angles to the length of the signpanels, for purposes of connection, bracing, andstructural rigidity.



Appendix B • References

Highway Traffic Act (HTA); Office Consolidation,Revised Statutes of Ontario, 1990, Chapter H.8and the Regulations thereunder (as amended);Queens Printer for Ontario, March 1996

King’s Highway Guide Signing Policy Manual; Ministryof Transportation Ontario, 1990

Manual of Uniform Traffic Control Devices (MUTCD);Ministry of Transportation, Ontario, 1995

Manual on Uniform Traffic Control Devices; U.S.Department of Transportation, 2003

Manual of Uniform Traffic Control Devices (MUTCDC);Transportation Association of Canada, 1997

Occupational Health and Safety Act (OHSA) andRegulations; Revised Statutes of Ontario, QueensPrinter for Ontario, 2001

Ontario Traffic Manual, Books 1 to 9; University ofToronto Press, various dates

Traffic Signing Handbook; Institute of TransportationEngineers, 1997

Workplace Hazardous Materials Information System;Health Canada, administered through federal andprovincial ministries, 2000.

sign design, fabrication & patterns

Documents