Cart empty
The Safety Zone Report
Last month in Denver, a municipal road crew was patching potholes on a busy roadway when a distracted driver plowed through their work zone at 45 mph. The workers survived only because their Class 3 high-visibility vest caught the driver's attention at the last second, allowing him to dive behind a concrete barrier. This near-miss illustrates why selecting the best safety equipment for municipal road crews isn't just about compliance—it's about ensuring workers return home each day. 30 workers were killed after being struck by vehicles in work zones according to 2024 Bureau of Labor Statistics data.
In 2023, 5,283 workers were killed on the job in the U.S., with 385 deaths each day due to hazardous working conditions. Road maintenance and construction work exposes crews to moving traffic, heavy machinery, and hazardous materials. Workers need comprehensive protection that meets federal standards and addresses real-world risks. This guide covers the essential safety equipment that keeps municipal road crews protected while they maintain our infrastructure.
Why the Best Safety Equipment for Municipal
Road Crews Matters
Municipal road crews work in one of the most dangerous environments. 52% of worker fatalities were due to workers on foot being struck by vehicles on the job site. These workers face multiple hazards daily.
Heavy traffic creates the primary risk. Drivers often fail to slow down or pay attention in work zones. About 96,000 crashes occurred in work zones in 2022 alone.
Visibility challenges compound the danger. Early morning fog, rain, and nighttime conditions make workers nearly invisible to passing motorists. Construction equipment adds another layer of risk as operators may have limited sight lines.
Federal regulations require specific safety standards for good reason. The Manual on Uniform Traffic Control Devices (MUTCD) Section 6D.03 requires the use of high-visibility safety apparel by workers who are working within the rights-of-way of Federal-aid highways.
Compliance protects workers and shields municipalities from liability.. These relatively low penalties underscore the importance of proactive safety measures rather than reactive compliance.
PPE Essentials for Road Crews
Personal protective equipment forms the first line of defense for road crews. Each piece serves a specific purpose in preventing injuries and saving lives. The PPE Zone offers comprehensive protection solutions for municipal crews.
Municipal road crews must use PPE that meets specific federal standards including ANSI/ISEA 107 for high-visibility apparel and OSHA 1910.132 for general personal protective equipment requirements. These standards ensure each piece of equipment provides adequate protection against documented workplace hazards while maintaining functionality in demanding work environments.
High-Visibility Apparel
High-visibility clothing represents the most important safety investment for road crews.
All workers within the right-of-way who are exposed to traffic or work vehicles must wear high-visibility safety apparel that meets the Performance Class 2 or 3 requirements of the ANSI/ISEA 107-2004 standard.
The ANSI/ISEA 107-2020 standard also classifies high-visibility gear into Type O (Off-Road), Type R (Roadway), and Type P (Public Safety), ensuring correct apparel selection for all work environments. Type R apparel specifically addresses roadway hazards and provides the protection municipal crews need.
Class 2 safety apparel requires minimum background material of 775 square inches and minimum retroreflective material of 201 square inches. This level works for traffic speeds exceeding 25 mph and suits most municipal road work.
Class 3 apparel provides maximum protection with minimum background material of 1,240 square inches and minimum retroreflective material of 310 square inches. Garments must have sleeves to meet Class 3 requirements. This level works best for nighttime operations and flagging duties on high-speed roads.
Municipal crews can enhance team identity and professionalism with custom logo vests that maintain safety standards while displaying department branding.
Protective Headgear
Hard hats protect against falling objects, overhead hazards, and electrical contact.
Municipal road crews face risks from tree branches, construction debris, and equipment impacts.
Regular inspection prevents equipment failure. Check for cracks, dents, or worn suspension systems before each use. Replace hard hats immediately after any significant impact, even if damage isn't visible.
Eye and Facial Protection
Road work exposes crews to flying debris, chemical splashes, and bright sunlight. A worker in Phoenix suffered a corneal abrasion when asphalt chips flew up during milling operations—an injury that could have been prevented with proper safety glasses.
There are a variety of safety glasses options. Safety glasses with impact-resistant lenses, wraparound designs, comfortable frames, or anti-fog coatings to help maintain clear vision in humid conditions.
Make sure to clean lenses regularly and replace scratched or damaged eyewear immediately to prevent your vision from being obstructed.
Gloves and Hand Safety
Your hands face constant exposure to cuts, chemicals, vibration, and temperature extremes. The right gloves protect against specific hazards while maintaining dexterity.
Cut-resistant gloves prevent injuries when handling sharp materials or broken glass. Look for gloves rated for the specific cut level your crews encounter.
Chemical-resistant gloves protect against fuel, oils, and cleaning solvents. Nitrile and neoprene gloves offer good chemical resistance with reasonable dexterity.
Cold weather gloves maintain hand warmth and flexibility during winter operations.
Insulated gloves with grip-enhanced palms work well for most municipal tasks.
Replace gloves when they show signs of wear, cracking, or contamination. Damaged gloves provide false security and may increase injury risk.
Traffic Control Solutions and Roadside Equipment
Traffic control equipment creates safe work zones by directing vehicles away from crews and clearly marking hazards. The Work Zone Safety category provides comprehensive solutions for municipal operations.
Proper traffic control reduces vehicle-worker conflicts and helps drivers navigate work zones safely. Equipment must meet MUTCD standards and remain visible in all weather conditions.
Barricades and Delineators
Barricades create physical barriers between workers and traffic. Type I, II, and III barricades serve different functions based on road conditions and traffic volume.
Type I barricades work well for sidewalk closures and minor obstructions. Type II barricades handle lane closures and intermediate traffic control. Type III barricades provide maximum visibility for major road closures.
MUTCD requires Type I and II barricades to be at least 24 in long and Type III barricades must be at least 48 in long. These specifications ensure adequate visibility and recognition by approaching drivers.
Delineators guide traffic through work zones with flexible posts that bend without breaking. Reflective bands make them visible at night and in poor weather.
Position barricades and delineators according to MUTCD guidelines. Proper spacing and alignment help drivers understand the work zone layout and navigate safely.
Traffic Cones
Traffic cones provide flexible traffic control that crews can deploy and move quickly.
Traffic cones with reflective bands offer maximum visibility to approaching drivers,
especially at night.
Make sure to use appropriate cone sizes for your application. Larger cones provide better visibility on high-speed roads. Weighted bases prevent wind from moving cones out of position.
When cones are used on freeways and other high-speed highways or at night on all highways, or when more conspicuous guidance is needed, cones shall be a minimum of 28 in. in height.
Safety Signs
Signs come in mesh, vinyl (non-reflective or reflective) and rigid, in 36” or 48” sizes.
Signs deliver clear messages to drivers about work zone conditions. Reflective signs are best at night and in poor weather. On freeways & expressways, MUTCD requires that signs be 48” for increased visibility.
The MUTCD has many standard legends that can be imprinted on the signs. Some of the most common include "Road Work Ahead," "Utility Work Ahead," or "Men Working." Besides the standard MUTCD legends, custom signs are available allowing you to address specific local conditions or temporary traffic patterns.
Inspect signs regularly for damage, fading, or dirt buildup. Clean or replace signs that don't provide clear visibility.
Specialty and Custom Safety Solutions
Some municipal operations require personalized safety equipment or safety equipment beyond standard PPE and traffic control devices. The Specialty Zone offers custom or non-standard solutions, such as vehicle lights or alarms.
Emerging technologies like LiDAR sensor trials in Bellevue's Vision Zero Action Plan and AI-enabled safety analytics offer real-time hazard detection improvements on work sites.
Winter operations need additional visibility aids like reflective tape and enhanced lighting systems. Storm cleanup requires specialized protective equipment for handling debris and hazardous materials.
Custom safety solutions help municipalities address specific local conditions. Reflective vehicle markings, specialized warning lights, and custom signage improve safety while maintaining professional appearance.
Equipment Maintenance and Inspection Routines
Regular maintenance keeps safety equipment functioning properly and extends service life. PPE used daily, such as gloves or eyewear, should be inspected before each use, while less frequently used gear can be inspected monthly or quarterly.
Create inspection checklists for different equipment types. Check for cracks, wear, fading, or damage that could compromise protection. Document inspections and repairs to maintain compliance records.
The WSDOT Safety Procedures Manual recommends creating tailored checklists for daily and monthly equipment inspections to ensure compliance. These systematic approaches help identify problems before they cause equipment failures or safety incidents. Consider implementing a digital maintenance log or software to automate inspection scheduling and repair tracking for all PPE and traffic control devices.
Store equipment properly to prevent damage. Keep PPE in clean, dry locations away from chemicals and extreme temperatures. Store traffic control devices where they won't be damaged by vehicles or weather.
Replace equipment before it fails. Set replacement schedules based on manufacturer recommendations and actual wear patterns. Budget for regular equipment replacement to avoid emergency purchases.
Train crews on proper equipment care and inspection procedures. Workers who understand equipment limitations and maintenance needs help prevent accidents and extend equipment life.
Ensuring Optimal Protection with the Best Safety Equipment for Municipal Road Crews
Municipalities need systematic approaches to safety equipment procurement and management. Start by assessing current equipment against federal standards and local hazards.
Budget for comprehensive safety programs that include initial equipment purchase, ongoing maintenance, and regular replacement. Quality safety equipment costs more upfront but provides better protection and longer service life.
Train supervisors and workers on proper equipment selection, use, and maintenance.
Regular safety meetings reinforce proper procedures and identify equipment problems before they cause injuries. Leverage ATSSA's training resources—over 40 courses in late 2024 plus the 2025 Annual Meeting and Traffic Expo with 40 educational sessions—to keep crews up to date.
Establish accountability systems that make safety equipment use mandatory, not optional. Supervisors must enforce safety standards consistently to build a culture where workers expect and demand proper protection.
Track safety performance and equipment effectiveness. Monitor injury rates, near-miss incidents, and equipment failure patterns to identify improvement opportunities.
Next Steps: Implementing the Best Safety Equipment for Municipal Road Crews
Municipal road crews deserve the best protection available. Investing in comprehensive safety equipment reduces injuries, saves lives, and protects municipalities from liability.
Safety Zone Specialists provides expert guidance and quality equipment for municipal operations. With over 30 years of experience, we understand the unique challenges facing road crews and offer solutions that work in real-world conditions.
Don't compromise on safety equipment quality or compliance. The best safety equipment for municipal road crews combines proven protection with practical functionality that workers will actually use. Schedule your free safety assessment today and explore our full range of solutions designed to keep your crews safe and compliant.
According to the National Institute for Occupational Safety and Health (NIOSH), work zone crashes remain a leading cause of occupational injuries. In this guide to ANSI Safety Apparel Ratings, we'll break down how the standard's Types (O, R, P) and Classes (1–3) help you choose life-saving high-visibility gear for every work environment.
Understanding ANSI Safety Apparel Ratings helps you choose the right protection for your specific work environment and keeps your team safe from preventable accidents. The American National Standards Institute sets these ratings to regulate apparel visibility and protection across different industries, ensuring workers remain visible to equipment operators, drivers, and other personnel who might otherwise miss them in busy work zones.
The Basics of ANSI Safety Apparel Ratings
ANSI began developing safety standards in 1918, evolving from the American Engineering Standards Committee into today's comprehensive standards organization. The first high-visibility safety apparel standard, ANSI/ISEA 107-1999, was largely based on existing European standards and has undergone regular updates to improve worker protection.
The current standard, ANSI/ISEA 107-2020, combines fluorescent background materials with retroreflective strips to make workers visible in various lighting conditions while organizing safety apparel into three distinct types based on work environment:
Type O (Off-Road) garments protect workers in non-roadway environments like warehouses and loading docks. These workers face vehicle hazards but don't work near public roads.
Type R (Roadway) apparel meets requirements for workers exposed to roadway traffic. This includes construction crews, utility workers, and anyone working within road rights-of-way.
Type P (Public Safety) gear serves law enforcement and emergency responders who need quick access to equipment while maintaining visibility. These garments often feature shorter designs to accommodate duty belts and gear.
Each type comes in different performance classes that determine the amount of visible material required. The ANSI/ISEA 107-2020 standard specifies exact material requirements for each combination:
- Type O Class 1 – 217 in² background, 155 in² reflective
- Type R Class 2 – 775 in² background, 201 in² reflective
- Type R Class 3 – 1,240 in² background, 310 in² reflective
- Type P Class 2 – 450 in² background, 201 in² reflective
- Type P Class 3 – 775 in² background, 310 in² reflective
All ANSI-compliant garments must carry a label indicating ANSI/ISEA 107-2020 compliance, the garment Type, and Performance Class. This classification system ensures workers get appropriate protection based on their specific hazards and work environments.
Key Differences in ANSI Safety Apparel Ratings
ANSI classes differ significantly in their visibility requirements and material specifications. Understanding these differences helps you select appropriate protection for each work situation.
Class 1 ideal for low-risk zones (warehouses, parking lots).
Class 2 ideal for road construction workers, airport ground crews, and flaggers typically wear Class 2 apparel. The Manual on Uniform Traffic Control Devices requires Class 2 or higher for all roadway workers (MUTCD Section 6D.03) [FHWA].
Class 3 garments resemble short-sleeve shirts due to their extensive coverage requirements. Class 3 apparel suits high-speed traffic environments, nighttime operations, and situations where workers cannot devote full attention to surrounding hazards.
The retroreflective strips must provide 360-degree visibility with horizontal gaps of 50mm or less. Garments without reflective sleeves need additional shoulder reflective material to maintain proper visibility angles.
Selecting the Right Apparel for Your Work Environment
Choosing appropriate ANSI-rated gear depends on your specific work conditions and regulatory requirements. Different job roles demand different protection levels based on traffic speed, equipment proximity, and environmental factors.
Delivery drivers and warehouse workers typically need Class 1 protection when working in controlled environments with slow-moving vehicles. Municipal workers, construction crews, and airport personnel require Class 2 apparel for medium-risk environments with moderate traffic speeds.
Highway construction workers, emergency responders, and utility crews working near high-speed traffic need Class 3 protection. Survey crews and tow truck operators also benefit from maximum visibility apparel due to their exposure to fast-moving vehicles.
Background materials come in fluorescent yellow-green, fluorescent orange-red, and fluorescent red to maximize daytime visibility. Consider seasonal requirements when selecting safety apparel. Safety winter gear maintains ANSI compliance while providing cold-weather protection. Waterproof rain gear keeps workers visible and dry during adverse weather conditions.
At Safety Zone Specialists, we provide ANSI-certified apparel for all work environments. Our selection includes safety vests and hi-viz safety shirts in various classes and configurations to meet your specific needs. For traffic control and signage in addition to hi-vis gear, visit our Work Zone Safety category.
Proper Care and Maintenance for Longevity
Maintaining high-visibility apparel preserves its protective properties and extends service life. Proper care practices keep retroreflective materials effective and background colors bright.
Machine wash safety apparel in cold water using mild detergents. Avoid bleach and fabric softener, which can damage retroreflective strips and fade fluorescent colors. Don't wash high-visibility clothing with rough fabrics like denim that might damage adhesive bonds.
Inspect garments before each shift for signs of wear, fading, or damage. Clean visible dirt and dust after each use to maintain optimal visibility. Check retroreflective strips for peeling, cracking, or loss of reflectivity. Best practices recommend inspecting reflective strips for cracking or delamination.
Replace daily-use hi-vis apparel every six months; occasional-use garments may last up to three years, depending on wear and care [BorderStates]. Replace apparel that shows fading, tears, or reduced reflectivity. Garments should remain visible at 1,000 feet during both day and night conditions. Effectiveness matters more than age when determining replacement needs.
Proper storage in cool, dry locations away from direct sunlight helps preserve fluorescent colors and retroreflective properties. Regular maintenance and timely replacement ensure continuous compliance and optimal worker protection.
Why ANSI Safety Apparel Ratings Matter
Explore our full catalog of ANSI-certified hi-vis gear in the PPE Zone to outfit your team today. The construction industry faces mounting pressure to reduce workplace incidents while maintaining productivity. ANSI Safety Apparel Ratings give you the tools to protect workers systematically, but implementation requires commitment from leadership and consistent enforcement at every level. Companies that prioritize compliant safety gear see measurable reductions in incident rates and insurance costs.
Investing in quality ANSI-certified apparel demonstrates your commitment to worker safety and regulatory compliance. The right gear reduces accident risks, minimizes liability exposure, and creates a culture of safety awareness.
Safety Zone Specialists brings over 30 years of experience helping organizations select appropriate safety solutions. Learn more about our 30-year history on our About Us page. Our comprehensive inventory includes ANSI-certified apparel for every work environment, from basic warehouse operations to complex roadway construction projects.
Ready to upgrade your team's high-visibility gear? Visit our PPE Zone to browse ANSI-certified vests, jackets, and specialty items, or contact us for a personalized safety plan.
