Missing a single channelizer, faded sign, or uncharged message board can shut down your work zone, idle crews at $2,000+ per hour, and trigger Caltrans or local-agency violations costing $5,000–$50,000. Safety Network Inc., California’s largest traffic control equipment provider with 15 years of experience, has supported 2,500+ installations with 100% compliance and zero downtime incidents. This comprehensive checklist—organized into seven essential categories—ensures every setup meets MUTCD, Caltrans Standard Plans, and OSHA requirements. Visit Safety Network Inc. or follow us on LinkedIn and Facebook for downloadable PDF versions.
Experienced contractors know the pain of arriving on site only to discover “we forgot the advance warning signs” or “the arrow board battery is dead.” Safety Network Inc. maintains pre-loaded kits and 24/7 delivery to eliminate those risks. A Fresno freeway project avoided $32,000 in liquidated damages because our checklist caught a missing buffer-space channelizer before inspection. Use this guide to build flawless work zones every time.
Category 1: Advance Warning Signs (First Driver Impression)
MUTCD Requirement: Three-phase advance warning on high-speed roads (G20-1, G20-2, G20-3 series). Checklist Items:
- “Road Work Ahead” (48×48 inch, Diamond Grade)
- “Right Lane Closed 1 Mile” / “500 Ft” / “Merge Left” sequence
- “Be Prepared to Stop” (optional but recommended for queues)
- Bilingual versions for urban areas (equipment)
Quantity Rule: One set per direction, plus extras for phased changes. Pro Tip: Safety Network Inc. pre-packages advance warning kits with reflective stands—no assembly on site.
Category 2: Channelizing Devices & Tapers
Core Items:
- 28-inch or 42-inch traffic cones (with 2 reflective collars)
- 42-inch tubular markers for long-term
- Vertical panels or drums for emphasis
- Type I, II, or III barricades for full closures
Taper Spacing (MUTCD Table 6C-3):
- ≤40 mph: 25 ft spacing
- 45–55 mph: 50 ft spacing
- ≥60 mph: channelizers every lane width (12 ft)
Buffer Space: Minimum 100 ft before work area—no devices. Our Stock: 8,500+ cones ready for immediate delivery.
Category 3: Arrow Boards & Portable Changeable Message Signs (PCMS)
Arrow Boards:
- Type C (60×30 inch) minimum for California highways
- Full sequential chevrons + caution mode
PCMS:
- Full-matrix, 18-inch characters, 3-line capability
- Pre-programmed Caltrans-approved messages
Placement: Arrow board at taper start; PCMS 1 mile, ½ mile, and 1,000 ft advance. Power: Solar + battery backup (35-day runtime).
Category 4: Truck-Mounted Attenuators (TMAs) & Shadow Vehicles
MASH Compliance:
- TL-3 (70 mph) for ≥55 mph zones
- Minimum 26,000 lb GVWR host truck
Checklist:
- Scorpion II or Verdek VPS cartridge (current certification)
- 60×30 inch arrow board mounted
- 4-corner strobes + work lights
- Impact camera recommended
Safety Network Inc. maintains 180+ MASH-certified TMAs.
Category 5: Pedestrian & Bicycle Protection (ADA Compliance)
Mandatory Items:
- 5-ft minimum covered walkway (detectable edging)
- Temporary curb ramps (1:12 slope)
- “Sidewalk Closed – Cross Here” signs
- Bike lane detour signage (C30-14 series)
Common Rejection: Missing handrails on temporary ramps. Our Kit: Pre-assembled ADA pedestrian bundles—pass inspection every time.
Category 6: Lighting & Visibility for Night/Weather
Illumination: 10 fc minimum in work area (OSHA 1926.56). Items:
- Portable LED light towers (40,000–120,000 lumens)
- Balloon lights for glare-free
- Retroreflective vests (Class 2 or 3) for all workers
- Fog-line delineators
Weather Contingency: Extra strobes and “Reduced Speed” signs for rain/fog.
Category 7: Documentation & Support Items
On-Truck Essentials:
- Printed TCP with revision date
- MASH eligibility letters for TMAs
- Daily inspection logs
- Emergency contact sheet (CHP, tow, medical)
- First-aid kit & fire extinguisher
Digital: Safety Network Inc. provides QR-coded compliance packets—scannable by inspectors.
Why Safety Network Inc. Makes Checklists Foolproof
- 10,000+ items in inventory—no “out of stock” surprises
- Pre-built kits tailored to Caltrans Standard Plans T9–T14
- 24/7 delivery anywhere in California
- Full maintenance and inspection service included
Download our free printable checklist at Safety Network Inc..
Frequently Asked Questions
How many cones for a 500-ft taper at 60 mph? Approximately 42 (12-ft spacing).
Night work lighting requirement? 10 fc average, 5 fc minimum in work area.
ADA walkway width? 60 inches minimum clear path.
Do you rent full kits? Yes—pre-loaded trailers ready to roll.
Where to get the checklist? Free PDF at Safety Network Inc..
Build Flawless Work Zones Every Time
Missing equipment wastes money and endangers lives. Safety Network Inc.’s seven-category checklist guarantees complete, compliant setups.
Visit Safety Network Inc. or follow on LinkedIn and Facebook.
Your crew—and the traveling public—deserve nothing less than perfection.