Keeping your traffic safety equipment in peak condition is essential for protecting crews and motorists. However, even the best-maintained devices eventually age out of compliance or efficiency. At Western Highways Traffic Safety, we recommend a full equipment overhaul whenever you spot any of these five clear signs. By acting proactively, you avoid costly downtime, ensure regulatory compliance, and maintain the highest level of work-zone protection.
1. Frequent Breakdowns and Unplanned Repairs
First and foremost, if you’re calling for emergency repairs more than once a month, your gear is signaling distress:
- Repeated TMA Impacts: Even minor collisions wear out crush modules and mounting hardware.
- Arrow Boards Failing to Illuminate: LED failures or wiring shorts during deployments.
- Light Mast Malfunctions: Hydraulic or mechanical lift failures under load.
Moreover, each unplanned service call costs labor, parts, and lost productivity. Consequently, bundling these fixes into a single overhaul often saves time and money.
2. Rising Maintenance Costs Per Unit
Furthermore, track your maintenance budget closely. You’ll notice:
- Spiking Parts Expenses: Frequent replacement of batteries, lamps, or control modules.
- Increased Labor Hours: Technicians spending more time troubleshooting older systems.
- Downtime Penalties: Project delays that trigger liquidated damages or weekend work.
When your annual maintenance bill exceeds 30% of a new unit’s value, it’s time to consider a comprehensive rebuild or replacement.
3. Outdated Technology and Compliance Gaps
In addition, regulations evolve. Equipment purchased a decade ago may no longer meet current standards:
- MUTCD Updates: New requirements for arrow board visibility and VMS messaging per MUTCD Part 6F.
- OSHA 1926.200: Enhanced flagger-protection criteria affecting AFAD deployment.
- Caltrans Specifications: Revised attenuator testing (MASH TL-4) for critical highway zones.
As a result, using legacy gear can expose you to compliance risks. A full overhaul lets you upgrade to MASH-certified attenuators, higher-intensity LEDs, and remote-controlled safety enclosures that satisfy today’s codes.
4. Declining Performance & Reliability
Moreover, consistent output is crucial. Watch for:
- Slow Response Times: Delayed arrow-board pattern changes or lamp startup lags.
- Weakened Signal Strength: Telemetry systems losing GPS accuracy or remote-control range.
- Diminished Attenuation: TMA cartridges compress unevenly, reducing crash energy absorption.
Such performance drops compromise safety. By contrast, a complete equipment overhaul replaces wear-prone components and recalibrates systems to “like new” operation.
5. High Utilization in Harsh Environments
Finally, equipment used heavily on rough roads or in extreme weather degrades faster:
- Corrosion & Rust: Salt, moisture, and UV exposure damage metal frames and electronics.
- Vibration Fatigue: Continuous off-road travel fatigues welds, mounts, and circuit boards.
- Battery Wear: Deep cycling and temperature swings shorten battery lifespan dramatically.
If your fleet spends more than 1,000 hours per year in service—or operates frequently in coastal or winter conditions—plan for an annual or biennial overhaul to address cumulative wear.
Planning Your Overhaul: Key Steps
- Inventory Audit: Catalog each unit’s age, hours in service, and repair history.
- Performance Testing: Conduct field tests on attenuator energy absorption, light output, and telemetry accuracy.
- Regulatory Review: Compare equipment specs to current MUTCD, OSHA, and Caltrans requirements.
- Cost–Benefit Analysis: Weigh rebuild vs. replacement costs, factoring in downtime and compliance risk.
- Overhaul Schedule: Phase work across off-peak seasons to minimize impact on active projects.
By following this structured approach, you ensure a smooth transition and maintain uninterrupted work-zone safety.
Conclusion
A full equipment overhaul isn’t just a major repair—it’s an investment in reliability, compliance, and crew protection. If you recognize frequent breakdowns, rising maintenance bills, outdated technology, declining performance, or heavy-duty wear, contact Western Highways Traffic Safety for a comprehensive assessment and rebuild plan.
Contact Us
Secure your work zones with overhauled, code-compliant equipment:
- Phone: +1 (559) 785-1400
- Email: info@westernhighwaystrafficsafety.com
- Website: westernhighwaystrafficsafety.com
