District 2 photo by Chris Woodward
By Haleigh Pike
District 2 information officer
One of the lesser-known but essential parts of District 2 is its sign shop, where signs that guide millions of motorists every year are meticulously crafted.
These signs are more than just pieces of metal with words, they represent safety, navigation and communication on the road.
A vital part of any transportation system, road signs communicate necessary information to drivers, such as speed limits, directions and warnings about road conditions or hazards. Each sign is designed with care and precision while adhering to strict standards and without them, navigating California’s roads would be a confusing and dangerous endeavor.
The District 2 sign shop has been a hub of activity since it was brought back to the district in 2023. Spearheaded by former Deputy District Director of Maintenance and Operations Michael Webb to minimize the growing financial commitment in keeping our roadway signs up to standard, the sign shop supports the district with the production, repair and customization of signs that end up on our highways and bridges.
“Having the District 2 sign shop up and running has not only saved the district a significant amount of money, but the state. The monetary value is a huge plus, but the long order and delivery time frames endured by maintenance crews while waiting on replacement signs has been shortened drastically,” said Sign Crew Supervisor Billy Shakespeare.
Training to work in the sign shop is a rigorous process that blends technical skills, safety awareness and a thorough understanding of road sign regulations. Workers are trained on specialized equipment and follow strict safety protocols, but the real training for District 2 was when they were able to work with the equipment.
District 2 photo by Chris Woodward
“There is some initial training for employees. However, a large amount of knowledge is learned when working hands-on through trial and error,” said Shakespeare. “Districts 3 and 4 have also been a huge help through this process by sharing knowledge and expertise. We have sent employees to their facilities, and they have sent theirs to ours.”
Before the physical process of making a sign begins, engineers and planners decide on the size, shape, color and content of each sign based on national and state regulations. The Manual on Uniform Traffic Control Devices outlines the specific fonts, sizes and reflectivity levels required for road signs to ensure consistency across the country.
For Caltrans, creating a sign means we also must take into consideration factors such as visibility at different times of the day, under various weather conditions, and from different angles and distances, especially for large freeway signs.
The process of creating the sign is both an art and a science. After the design is transferred onto the aluminum backing, the signs are cut to appropriate size. After the sign is cut and assembled, it goes through an extensive inspection process to check for accuracy in design, spelling and reflectivity. Even the smallest mistake could lead to confusion on the road, so attention to detail is paramount.
Unlike many other districts that rely on outside vendors or specialized contractors, the District 2 sign shop has developed the in-house ability to perform fabrication and welding of sign frames. By welding and fabricating frames in-house, District 2 is saving both time and money, which is especially valuable when road signs are damaged by weather or accidents.
This also allows District 2 to have direct control over the materials and techniques used, as the signs in District 2 often need to endure more extreme conditions, thus needing to be produced to the highest standards of durability to ensure longer-lasting infrastructure and less frequent need for repairs or replacements.
The work of the District 2 sign shop directly contributes to road safety by providing clear, readable signage that communicates critical information to drivers. Whether you’re cruising down Interstate 5 or navigating a rural road, the signs that keep you on track are a result of hard work, innovation, and careful planning at the District 2 sign shop.