Better work zones start with better answers.
Choose the right cone, compare sign sizes, decode reflective materials, and plan safer setups—without digging through a 1,000-page manual.
Start with the numbers.
Two existing calculators, a cone quantity planner, and two new material estimators, in one place.
Work Zone & Taper Calculator
Calculate example merging-taper lengths, longitudinal buffers, advance warning spacing, and device intervals using roadway inputs.
Open calculator ↗Sign Sizing & Placement
Review roadway-based sign sizing, mounting heights, lateral clearance, and placement-distance references.
Open calculator ↗Traffic Sign Material & Sheet Yield
Calculate square footage, compare 36″ and 48″ blanks, estimate aluminum sheets and reflective sheeting allowance. Shows the exact cutting assumptions.
Estimate sign materials ↗Parking Lot & Road Stripe Paint
Estimate lineal footage, painted area, gallons at a specified wet-film thickness, and purchase allowance. Supports solid or intermittent stripes.
Estimate stripe paint ↗How Many Cones Do I Need?
Use a measured line length and planning speed to estimate an initial cone count before final field adjustments.
Estimate cones ↓What traffic cones should I use?
Make a first-pass selection based on roadway speed, nighttime use, and the job location.
Find a starting point
This selector summarizes the federal baseline; state and contract requirements may be stricter.
Daytime, lower-speed roadway baseline
An 18-inch minimum is the federal starting point for cones used in daytime, low-speed roadway conditions. The project or agency may call for 28-inch cones anyway.
These calculations provide preliminary reference estimates based on FHWA MUTCD 11th Edition (Rev 1, Dec 2025) guidelines and do not constitute approved engineering designs or traffic-control plans. Results must be independently verified by a qualified traffic engineer against site conditions and local specifications before use. Full legal disclaimer →
Federal minimum for daytime, lower-speed roads. Often better suited to controlled, lower-speed environments.
Browse 18″ cones on Amazon ↗Federal minimum for nighttime or freeway / high-speed roadway use. Verify collars and base stability.
Browse reflective 28″ cones ↗Additional visibility and presence; check the different reflective band arrangement for cones taller than 36″.
Browse 36″ cones ↗Shopping links open Amazon search results, not inspected or endorsed products. No affiliate tracking is included. Product descriptions alone do not establish MUTCD compliance.
Estimate your cone quantity.
Useful for preparing a materials list—not for deciding the taper length or layout.
Spacing figures are MUTCD *guidance maximums*, not automatic placement requirements. Actual spacing may need to be tighter. Count includes endpoints for one continuous line.
For a 300-ft taper line at 35 mph, use no more than 35 ft as the initial spacing guide.
These calculations provide preliminary reference estimates based on FHWA MUTCD 11th Edition (Rev 1, Dec 2025) guidelines and do not constitute approved engineering designs or traffic-control plans. Results must be independently verified by a qualified traffic engineer against site conditions and local specifications before use. Full legal disclaimer →
36″ vs. 48″ work-zone signs.
The same legend, very different physical footprint. Context determines the right size.
WORK
AHEAD
36 × 36 inches
Common conventional-road size for W20-1 ROAD WORK and many other temporary warning signs.
WORK
AHEAD
48 × 48 inches
Listed freeway/expressway size for W20-1 and many comparable TTC warning signs.
The 48″ option is 33% taller and wider. That isn't a universal visibility guarantee, and sign sizes vary by designation, roadway, conditions, and local requirements. Do not substitute sizes purely on this visual comparison.
*Relative area is calculated from the squared nominal sign dimensions. This is a proportional comparison, not an absolute surface-area specification.| Sign example | Conventional road | Freeway / expressway | Reference |
|---|---|---|---|
| ROAD WORK (W20-1) | 36″ × 36″ | 48″ × 48″ | §6H.03 |
| DETOUR (W20-2) | 36″ × 36″ | 48″ × 48″ | §6H.04 |
| ROAD CLOSED AHEAD (W20-3) | 36″ × 36″ | 48″ × 48″ | §6H.05 |
| ONE LANE ROAD AHEAD (W20-4) | 36″ × 36″ | 48″ × 48″ | §6H.06 |
Selected table examples only; exceptions and minimum sizes exist. Confirm exact sign designation, current Table 6H-1, jurisdictional standards and traffic control plan.
Roll-up signs: what's the difference?
Choosing a portable sign is more than picking orange fabric and a stand.
Reflective vs. non-reflective
A roll-up material can be bright in daylight and still fail to return headlight illumination at night. Specify nighttime visibility performance, not just a color name.
Mesh vs. solid material
Mesh can reduce wind loading; solid materials can provide a more continuous face. Read the manufacturer's compatibility and visibility documentation before choosing.
Sign and stand as a system
Confirm the stand fits the intended sign dimensions, attachment system, height, wind exposure, and relevant crashworthiness / agency requirements.
Roll-up sign purchasing checklist
Ask the vendor for specifications, not just “MUTCD-style” marketing language.
- Correct legend, color and sign designation
- Proper sign dimension for the roadway
- Day/night retroreflectivity documentation
- Compatible stand and sign assembly
- Applicable agency or contract approvals
- Crashworthiness documentation when required
Reflectivity isn't one thing.
Understand what manufacturers mean before comparing signs or shopping listings.
Often labeled Type I
Traditional glass-bead performance category. Not a blanket answer for work-zone warning signs: FHWA guidance notes important limitations for Type I on yellow and orange backgrounds.
Prismatic alternatives
Prismatic materials redirect light toward its source. Different ASTM types and products have different performance; “high intensity” is not a substitute for a technical data sheet.
Advanced grades, including Type XI
Often selected for demanding applications or long service life. A higher grade doesn't excuse poor sign design, installation, maintenance, or agency approval.
References worth bookmarking.
We summarize common scenarios, but the applicable agency and current official standard are the final reference.
Common questions
Can I use 18-inch cones in any road work zone?
No. The federal 18-inch minimum is for daytime, lower-speed roadway conditions. At night or on high-speed roads/freeways, the federal baseline is at least 28 inches, with additional visibility requirements. States and contracts may impose stricter rules.
Are reflective collars always mandatory?
For nighttime cone use, the MUTCD requires retroreflectorization or lighting devices. The prescribed reflective stripe arrangement depends on cone height. Daytime-only scenarios and agency-specific requirements differ.
Is a 48-inch ROAD WORK sign always better?
Not automatically. It offers a larger face but must be matched to the roadway, required sign legend, mounting/stand system, space, and agency plan. Table 6H-1 lists common 36-inch conventional and 48-inch freeway/expressway sizes for many work-zone warning signs.
Does a roll-up sign need to be reflective?
For nighttime use, temporary traffic-control sign visibility must satisfy current MUTCD rules. Confirm the selected material and full portable assembly against the roadway agency's specification; never assume ordinary bright orange fabric is retroreflective.
Can I trust a product listing that says “MUTCD compliant”?
Treat that as a claim to verify. Check dimensions, material grade, reflective treatment, stands, crashworthiness where applicable, and agency requirements. An online listing is not a traffic-control plan or certification.