Traffic Sign Thickness Guide for Aluminum Street Signs

2026-01-19

The most common traffic sign thickness for custom aluminum traffic signs is .080 pouces. Many state DOTs, such as MaineDOT, adhere to this standard. Thicker options like .100″ or .125″ provide greater strength and are typically used for larger signs or in areas with strong winds. Par exemple, a 24″ stop sign utilizes .080″ matériel, while a 48″ stop sign requires .100″ or .125″ to withstand adverse weather conditions. DOTs determine traffic sign thickness based on the size or area of the sign. Always verify your local regulations before placing an order.

Taille de signe	Options d'épaisseur
48″ Panneau d'arrêt	.100″ or .125″
24″ Panneau d'arrêt	.080″

À OPTRAFIC, we offer custom panneaux de trafic en aluminium in a variety of sizes and thicknesses, including the standard 0.080-inch thickness for signs like the 24-inch traffic sign and 0.100-inch or 0.125-inch for larger signs like the 48-inch traffic sign. Whether you need a 24-inch traffic sign for residential areas or a 48-inch traffic sign for highways or locations exposed to harsh weather, OPTRAFFIC ensures that all your signs are crafted to meet local regulations and are built to perform in challenging conditions.

Common Traffic Sign Thickness Options

Ébauches de panneaux en aluminium: Standard Thicknesses

Ébauches de panneaux en aluminium are the base for most street and traffic signs in the U.S. These blanks come in different thicknesses. Each thickness works best for certain places and uses. Thicker blanks are stronger and last longer.

.040 inch aluminum sign blanks are good for signs used for a short time. These are best for places with little wind.
.063 inch aluminum sign blanks are stronger than .040 pouce. People use these in neighborhoods for less important signs.
.080 inch aluminum sign blanks are the main choice for important signs. Cities and states use this thickness for stop signs and yield signs.
.100 inch aluminum sign blanks are even stronger. Bigger signs or signs in busy places need this thickness.
.125 inch aluminum sign blanks are the toughest. These are used on highways and in construction zones, especially where weather is bad.

Conseil: Pick the right aluminum sign blanks by thinking about where the sign will go, how long it needs to last, and if it might face wind or damage.

Thickness Comparison Table

The table below shows how different ébauches de panneaux en aluminium comparer. It lists thickness, ce pour quoi ils sont utilisés, good points, bad points, and how to mount them. This helps you choose the right one for your needs.

Épaisseur (dans)	Épaisseur (mil)	Épaisseur (mm)	Duty Type	Cas d'utilisation typiques	Pros	Inconvénients	Mounting Notes
0.040	40	1.02	Light Duty	Signes temporaires, event parking, short-term notices	Léger, facile à manipuler	Not suitable for windy or high-traffic areas	Use with light-duty posts or frames
0.063	63	1.60	Light Duty	Residential street signs, private property signs	More durable than 0.040	Less rigid than thicker options	Works with standard mounting hardware
0.080	80	2.03	Standard Duty	Signes d'arrêt, signes de rendement, regulatory street signs	Industry standard, balances strength/weight	May flex on very large signs	Compatible with most sign posts
0.100	100	2.54	Medium Duty	Panneaux surdimensionnés, intersections à fort trafic	Increased rigidity, résiste à la flexion	Plus lourd, may require stronger supports	Use with reinforced mounting systems
0.125	125	3.18	Heavy Duty	Panneaux d'autoroute, zones de construction, windy locations	Maximum durability, résiste au temps dur	Heaviest, coût plus élevé	Needs robust mounting and supports

Most regulatory signs use .080 inch aluminum sign blanks. Thicker blanks like .100 ou .125 inch are better for bigger signs or signs in windy places.

Thickness Terminology: Pouces, Mils, Millimeters

Knowing how thickness is measured helps you pick the right ébauches de panneaux en aluminium. Makers use inches, milles, and millimeters to show how thick a blank is.

Pouces show thickness as a fraction or decimal, comme 0.080 pouce.
Mils mean thousandths of an inch, donc 80 mil is 0.080 pouce.
Millimeters are the metric way to measure, comme 2.03 mm pour 0.080 pouce.

Here is a table with the usual conversions for aluminum sign blanks:

Épaisseur (dans)	Épaisseur (mil)	Épaisseur (mm)
0.040	40	1.02
0.063	63	1.60
0.080	80	2.03
0.100	100	2.54
0.125	125	3.18

Note: 1 mil is 0.001 pouce, et 1 millimeter is 0.0394 pouce. Most aluminum sign blanks use these units in their product details.

Picking the right traffic sign thickness helps the sign work well where it is placed. Aluminum sign blanks come in many thicknesses for all kinds of signs, from short-term notices to permanent highway signs.

Flat vs Extruded Street Signs

Flat Panels and Stiffness

As is well-known, flat aluminum panels are the most commonly used material for street signs. The thickness helps the sign stay strong and not bend. Thicker panels make the sign stay flat in bad weather. A thick sign holds reflective layers better. This makes it easier to see at night or in storms. Cities pick thicker panels for windy or busy places. These signs last longer and need fewer fixes.

The table below shows how thickness changes the strength and use of flat street signs:

Épaisseur (pouces)	Avantages
0.080	Strong enough for daily use. It helps the sign stay flat and easy to read.
0.125	Stops bending and damage from strong winds and busy roads. It makes the sign last longer.
Des panneaux plus épais	Hold reflective layers better. They last longer and give a strong base for safety.

Picking the right thickness helps the sign follow safety rules. Thicker panels make the sign stronger. This means less bending and better visibility.

Extruded Panels and Edge Rigidity

Extruded street signs have a different design. These signs have special edges that add more strength. The edges work like a frame and make the sign stiffer. This design stops the sign from bending, even if the middle is not thick. Cities use extruded panels for big signs or windy places. The strong edges help the sign handle heavy loads and stay put.

Extruded panels are strong in two ways. The shape of the edge helps stop bending. The thick edges protect the sign from damage when installed or hit by cars. This makes extruded signs good for tough places.

Note: Flat panels use thickness for strength. Extruded panels use both thickness and edge design for maximum stiffness.

US DOT Thickness Requirements and Guidelines

The United States Department of Transportation (POINT) and state agencies have rules for picking the right traffic sign thickness for roads. These rules help signs follow MUTCD standards for safety and being easy to see. Each state can make its own rules, but most states use similar ideas based on how big the sign is. Here are three examples from Iowa, Géorgie, et le Texas. Pour plus d'informations sur la façon aluminum traffic sign thickness ensures MUTCD compliance, Consultez notre blog, L'épaisseur des signes de la circulation en aluminium et de son rôle dans la respect de la conformité MUTCD.

Size-Based Thresholds (POINT DE L'Iowa)

Iowa DOT looks at the longest side of a sign to pick the minimum aluminum thickness. This makes things simple and easy to remember. If the longest side is 36 inches or less, le signe doit être au moins 0.080 pouces d'épaisseur. If the longest side is more than 36 pouces, le signe doit être au moins 0.125 pouces d'épaisseur. Iowa DOT also uses ASTM B209 to check that the thickness is correct and meets national standards.

Longest Side of Sign	Minimum Thickness (pouces)	Application typique
≤ 36″	0.080	Standard stop/yield signs
> 36″	0.125	Large guide or warning signs

Iowa DOT’s way helps cities and counties pick the right traffic sign thickness for small and big signs. This method follows mutcd standards and keeps signs safe in all weather.

Area-Based Thresholds (Georgia DOT)

Georgia DOT uses the total area of the sign to pick the aluminum thickness. This works well for signs with odd shapes or big surfaces. If the sign is 9 square feet or less, ça doit être au moins 0.08 pouces d'épaisseur (plus or minus 0.005 pouces). If the sign is bigger than 9 pieds carrés, ça doit être au moins 0.10 pouces d'épaisseur (plus or minus 0.006 pouces). Georgia DOT also says signs must use 6061-T6 or 5052-H38 aluminum and meet ASTM B209 standards.

Sign Area (sq ft)	Minimum Thickness (pouces)	Alloy Requirement
≤ 9	0.08	6061-T6 or 5052-H38
> 9	0.10	6061-T6 or 5052-H38

Georgia DOT’s area method makes sure big signs stay strong and easy to see. This way follows mutcd standards and helps signs last longer outside.

Area Tiering (Txdot)

The Texas DOT (Txdot) uses a system that bases aluminum thickness on the sign’s area to ensure better strength. For signs smaller than 7.5 pieds carrés, the thickness must be at least 0.080 pouces. For signs between 7.5 et 15 pieds carrés, a minimum thickness of 0.100 inches is required. Signs larger than 15 square feet must have a thickness of at least 0.125 pouces.

Sign Area (sq ft)	Minimum Thickness (pouces)
< 7.5	0.080
7.5 - 15	0.100
> 15	0.125

TxDOT’s step system helps engineers and sign makers pick the right traffic sign thickness pour chaque travail. This way keeps signs safe and follows mutcd standards.

Note: DOT rules can change by state or project. Always check local rules before you order aluminum signs for roads.

Regardless of the regional requirements, OPTRAFIC, as an experienced road sign manufacturer, is capable of providing compliant signs for public works departments, sociétés de gestion du trafic, and traffic safety equipment rental services. We ensure that all signs meet the necessary standards for durability, visibilité, et conformité réglementaire.

Aluminum Alloys and Surface Prep

6061-T6 vs 5052-H38 Alloys

The type of aluminum alloy affects how long street signs last. Engineers usually pick between 6061-T6 and 5052-H38 for traffic signs. Each one works best in different places.

6061-T6 is strong and fits most city and highway signs. It does not bend easily and can handle daily use.
5052-H38 is called marine-grade aluminum. It fights rust better than 6061-T6. Cities near the ocean or with bad weather use this alloy more. It stands up to salty air and wet weather, Donc ça dure plus longtemps.
Both alloys make a shield on the outside. This shield keeps the metal from rusting and helps the sign last.
Some signs get powder coating for more protection. This coating makes the sign tougher and keeps it safe from sun, pluie, et la saleté.

Voici un tableau qui montre les différences:

Alliage	Force	Résistance à la corrosion	Cas d'utilisation typiques
6061-T6	Haut	Modéré	Urbain, autoroute, standard
5052-H38	Modéré	Haut	Côtier, industriel, harsh

To learn more about the advantages of using 5052-H38 aluminum for traffic control signs, n'oubliez pas de consulter notre blog, “Découvrez les avantages de l'aluminium 5052-H38 pour les panneaux de contrôle de la circulation”, where we explore its durability, résistance à la corrosion, and suitability for various environments.

Conversion Coating and Adhesion

Getting the surface ready is important for strong aluminum street signs. Conversion coating is a step before putting on reflective sheeting. This step helps the sheeting stick better and keeps the sign bright for a long time.

Good surface prep means cleaning and smoothing the aluminum. Clean aluminum lets the sheeting stick well. Smooth aluminum helps workers put the sheeting on evenly, which makes the sign last longer. Signs with good prep can fight off dirt and sunlight, so they stay shiny.

Conversion coating helps the reflective sheeting stick well. This is important for the sign to last and be easy to see.

Cities and states use these steps to make signs that work well and last in all kinds of weather.

Chargement de vent, Vibration, and Supports

Wind Load and Field Performance

Street signs can be pushed hard by the wind, especially in open or windy areas. According to the Iowa DOT, traffic signs must be able to withstand 30 pounds per square foot of wind pressure. This requirement ensures that signs remain secure during storms and strong winds.

Wind vibration is different at each site. It is hard to guess when it will happen. Steady winds and sudden gusts can shake a pole in many ways. If this happens a lot, it can hurt the pole. If the shaking is strong, it can make the metal or welds weak. They might crack even if the pole was built strong.

Wind vibration does not always break signs right away. But if it keeps happening, it can make signs or supports weak. Engineers check for problems like small cracks or loose bolts. They do this during regular checks. Picking the right thickness and support helps stop these problems. It keeps signs safe for people driving or walking.

To learn more about how to choose the correct aluminum thickness for your traffic signs based on wind load and size, Consultez notre blog, “How to Choose Aluminum Thickness for Traffic Signs Based on Wind Load and Size”, where we dive deeper into the factors to consider for long-lasting and durable signs.

Mounting Methods and Support Systems

Good mounting and support are important for aluminum street signs. Big signs or signs in windy places need more than thick aluminum. They need strong support so they do not bend or break.

Thick aluminum plates like 2.0 mm ou 3.0 mm make big signs stronger.
Extra bracing or a strong frame keeps signs steady in wind.
Steel channels or other braces help thin plates stay straight.
More posts give better support for big signs.
Special sign support systems help with very large or heavy signs.
Always check the manufacturer’s rules to pick the right post or support.

Dans des endroits venteux, support systems often use vibration isolation. This means using mounts or flexible parts that soak up shaking. These do not stop all vibration, but they make it less strong. It works like a seat that absorbs bumps on a train. By using the right thickness and good supports, cities help signs stay easy to see and safe, Même par mauvais temps.

Reflective Sheeting Types and Sign Blanks

ASTM D4956 Sheeting Types

The FHWA makes rules for reflective traffic signs. These rules use ASTM D4956 sheeting types. These types help drivers see signs at night or in bad weather. The table below shows the most common sheeting types for aluminum sign blanks:

Type de feuille réfléchissante	Visibilité	Description	Durabilité	Applications
Grade d'ingénieur (Type I)	~500 feet	Uses glass beads or prismatic tech; for non-critical signs	5–7 ans	Non-critical street signs, panneaux de stationnement
Prismatique à haute intensité (Type III & Iv)	~1000 feet	Micro-prismatic lens; très réfléchissant	~10 years	Panneaux de circulation, barricades, construction zone devices
Grade de diamant (Type XI)	~1500 feet	Cube complet prismatique; returns about 60% de la lumière	Longue durée	Critical traffic control signs like Stop and speed limit signs

Diamond grade sheeting is very bright. It reflects much more light than high intensity prismatic sheeting. This helps people see traffic signs from far away. Diamond grade lasts longer and fights off bad weather, saleté, et rouille. Cities use diamond grade for important signs to follow safety rules and keep roads safe.

Using strong sheeting like ASTM D4956 Type XI makes roads safer at night. Signs with better reflection help drivers see and follow rules.

Identifying Reflective Sheeting

Picking the right sheeting for traffic signs is important for safety and cost. The FHWA allows different types, like Engineering Grade, Super Engineering Grade, and High Intensity Beaded sheeting. Agencies should think about more than just price. They need to check how long the sheeting stays bright and how well it reflects light.

To find out what sheeting is on a sign, cherche ces choses:

Labels or marks on the back of the sign blank
Special patterns or textures on the sign’s surface
Color and brightness when headlights shine on it at night

Some rules say certain sheeting types cannot be used for white letters on overhead guide signs or for yellow backgrounds on warning signs. Always check local and federal rules before picking materials for traffic signs.

Conseil: When choosing sheeting, think about where the sign will go, how long it should last, and how easy it should be to see. Good reflective traffic signs help drivers react fast and keep everyone safe.

Choosing the Right Traffic Sign Thickness

Practical Checklist for Selection

Picking the right thickness for an aluminum street sign keeps people safe. It also makes the sign last longer and follow the rules. A simple checklist helps workers choose the best thickness for each job. The table below shows common thicknesses, ce pour quoi ils sont utilisés, and how much wind they can handle:

Jauge	Cas d'utilisation courante	Wind-Load Tolerance
0.040″	Light-duty lots, interior garages	Jusqu'à 30 mph
0.063″	Standard outdoor parking, suburban streets	30–50 mph
0.080″	Truck routes, coastal or high-wind areas	50 mph+

When making a sign, pense à ces choses:

How big the sign is and its area
How much wind will hit the sign
How the sign will be mounted
How tall the post is, especially if it is over 7 pieds
If the sign will be used for a short time or always
If moving or carrying the sign could damage it
How long the sign should last and how often it needs fixing

For traffic signs outside, 16–18 gauge (1.2–1.5 mm) is usually best. If you use a tall U-channel post, a thicker sign helps stop bending.

Conseil: Always pick the aluminum thickness that fits where the sign will go and how it will be mounted.

Erreurs courantes pour éviter

Choosing the wrong thickness for street signs can cause safety problems or cost more money. The most common mistakes are:

Using thin aluminum for big or windy signs, which can make them bend or fall off
Not making the sign thicker from .040″ à .063″ ou .080″ for outdoor or busy places
Forgetting to use thicker aluminum for bigger signs that need more support
Not checking the right thickness for the sign’s size and where it will be placed
Picking a thickness that does not fit what the sign needs

Note: Picking the right thickness at the start helps avoid problems and makes sure the sign works well for a long time.

Most street signs use .080″ aluminum because it is strong. This thickness helps the sign last a long time. Bigger signs or signs in windy places need thicker aluminum. These signs use .100″ or .125″ pour rester en sécurité. The table below shows which thickness works best for each place:

Type d'application	Épaisseur recommandée
Autoroutes, intersections occupées	0.080″ or 0.125″
Zones de construction	Plus épais, extruded signs
Rues résidentielles, parkings	0.040″ or 0.063″
Temporary or event signs	Thinner options

Always look at your local DOT rules. Ces règles aident à garder les panneaux sûrs et faciles à voir. Use the checklist and tables above to pick the right thickness for your project.

FAQ

What is the standard thickness for street signs?

Most street signs use 0.080-inch aluminum. This thickness provides a balance of strength and weight. Cities and states choose this size for stop, rendement, and regulatory signs.

Est 80 mil the same as 0.080 pouce?

Oui, 80 mil equals 0.080 pouce. Manufacturers often use “mil” to describe thickness. One mil means one-thousandth of an inch.

Should someone choose 0.063 ou 0.080 for parking lot signs?

Pour les parkings, 0.080-Inch Aluminium fonctionne mieux. It resists bending and lasts longer outdoors. Use 0.063-inch only for low-traffic or temporary signs.