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Bridges & Structures

Guidelines for the Installation, Inspection, Maintenance and Repair of Structural Supports for Highway Signs, Luminaries, and Traffic Signals

Appendix A Example Element Ratings

Foundation - S.01

photo of example element rating as described below
Figure A1
Buried Foundation
S.01 rate as '0', Not Applicable.
However, if opposite tower foundation is exposed, rate S.01 for that foundation, state in notes buried foundation and recommend as Priority 3 to expose.


photo of example element rating as described below
Figure A2
Deteriorated Grout Pad
S.01 rate as 3, Priority 2 repair.
Note also leveling nut corrosion (S.02 Item).
For Element Condition Rating, Ref. Table 10.
For Element Repair Priority, Ref. Table 11


Anchor Rods - S.02

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Figure A3
Missing Anchor Nut.
If Span structure, rate as 2, Priority Repair 2. If Cantilever structure, rate as 3, Priority Repair 1.


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Figure A4
Anchor rods not fully engaged.
If 80% threaded, note on report, rate S.02 as '1', no repair.
Loose Nuts (Washers Slip)
Less than 50% slip, rate S.02 as '2', Priority Repair 2.
More than 50% slip, rate S.02 as '2', Priority Repair 1.


Base Plate(s) - S.03

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Figure A5
Steel Base Plates
Rate as '1', Good Condition
No weld cracks, no cracks in base plate, and no visible warping.


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Figure A6
Buried Aluminum Base Plate
Rate as '0', Not Applicable.
However, if a span and opposite tower base plate is exposed, rate for that base plate, state in notes buried base plate and recommend as Priority 3 to expose. In any case all buried elements should be exposed per specification/plans.


Towers - S.04

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Figure A7
1" to 2" Band of surface corrosion at base of post. D-meter results indicate no overall section loss.
Rate 2, Small reduction of reliability.
However, if overall section loss in cantilever > 25%, rate 4, repair priority 1.


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Figure A8
Dent, tear, and weld crack in first strut on tower.
Rate as 2, Repair on Priority 3 basis.


Tower to Truss/Chord/Arm Connection(s) - S.05

photo of example element rating as described below
Figure A9
Gap between upper chord and shim pack and inadequate shim plate placement.
Rate 2, Repair priority 3.
Repair recommendation would be to properly place and add shim plates as necessary.


photo of example element rating as described below
Figure A10
Gap between lower chord and saddle block, loose u-bolt.
Rate 2, Repair as priority 3.
Repair recommendation would be to add shims under saddle block to close gap at chord. The inspector would tighten the u-bolt during inspection.


Truss Chords/Arms - S.06

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Figure A11
Minor surface corrosion observed on dual trussed arms.
Rate 1


photo of example element rating as described below
Figure A12
Minor 4" diameter ding in lower chord. Right rear end cap missing.
Rate 2, Repair priority 3


Truss Struts - S.07

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Figure A13
1.5" and 2.5" tears in strut member.
Rate 3, Repair Priority 1
Note: This strut has a cracked weld at the lower chord.


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Figure A14
2" +/- diameter defect in aluminum strut.
Rate 1
Note: The rating of 1 is for a structure with no other deficient struts. This structure's struts are actually rated 3 due to this and other deficiencies.


Cracks - S.08

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Figure A15
Weld crack in member U14 - L15 at L15. The weld crack is approximately 4" long x 1/8" wide and is propagating into the diagonal 1/2".
Rate 4, Repair priority 1


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Figure A16
1" long weld crack at lower chord.
Rate as 3, Repair priority 1


Chord Splice Connection(s) - S.09

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Figure A17
Three loose fasteners that could not be tightened by the inspector. Gap in chord splice.
Rate 3, Repair priority 2


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Figure A18
One of several severely deteriorated splice bolts.
Rate 4, Repair priority 1


Sign Frame and L-Brackets - S.10

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Figure A19
Missing one U-bolt at the lower chord to vertical sign member.
Rate 1, Repair priority 3


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Figure A20
Sign 5 exhibits severe impact damage with missing members and hardware.
Arrow shows broken bracket.
Rate 3, Repair priority 2


Sign Panels - S.11

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Figure A21
Sign 5 exhibits severe impact damage with approx. 1/2 the lower section of the sign panel missing, see arrow.
Rate 3, Repair priority 2


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Figure A22
Sign panel No. 2 was reused from old sign structure and is in fair condition.
Rate 1


Catwalk - S.12

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Figure A23
Portion of catwalk over main line above lanes 1,2 and 3 exhibits severe impact damage, and has apparently been removed from this section.
Rate 4, Repair priority 3


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Figure A24
The catwalk nosing exhibits moderate impact damage between the left most and middle light fixtures.
Rate 2, Repair priority 3


Power and Luminaires - S.13

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Figure A25
Lighting and framework has been removed. A section of abandoned conduit at the center of the truss is held in place by electrical wires on one end and one u-clamp at the other.
Rate 0, Repair priority 2
Repair priority 2 due to the inadequate attachment of the abandoned conduit.


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Figure A26
Lighting for sign #1 is missing due to impact damage. Exposed wires present.
Rate 4, Repair priority 2


Sign Attachment(s) - S.15

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Figure A27
Left rear post "No trucks in left lane" sign u-bolts are too large and sign is free to rotate.
Rate 2, Repair priority 3


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Figure A28
"No Trucks In Left Lane" (4' x 5') sign attached to the left rear post (facing the westbound traffic) exhibits moderate impact damage.
Rate 3, Repair priority 3


Vertical Clearance, Camber and Alignment - S.16

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Figure A29
Adequate camber, alignment and vertical clearance over all lanes under span.
Rate 1


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Figure A30
Adequate camber, alignment and vertical clearance over all lanes under the cantilever.
Rate 1


Protection - S.17

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Figure A31
Severe impact damage to guide rail. Damage to guide rail directly effects the protection of sign structure and motorist.
Rate 4, Repair priority 1
Note: This guide rail has since been replaced.


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Figure A32
Eastbound Loc. Rt Side: Impact damage to guide rail 3yds east of tower. Damage doesn't significantly impact protection of structure or motorist.
Rate 2


Other - S.18

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Figure A33
24 feet east of sign structure is an abandoned service pit with no cover.
Rate 4, Repair priority 2
The service pit/vault should be closed to protect the motorists.


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Figure A34
RTMS traffic device attached to right rear post.
Rate 1

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Updated: 07/30/2013
Federal Highway Administration | 1200 New Jersey Avenue, SE | Washington, DC 20590 | 202-366-4000