Start with your traffic control plan. Most work zone projects require a combination of advance warning signs, activity signs, and supplemental plaques. The MUTCD Part 6 defines standard sign layouts for common work zone configurations including lane closures, road closures, shoulder work, and flagging operations.
For sign size, match the road type. Conventional roads require 36" x 36" signs. Freeways and expressways require 48" x 48" signs. A 30" x 30" minimum is allowed only where traffic volumes are low and speeds are 25 mph or less. When in doubt, use the larger size.
For sheeting, check your project specifications. Many state DOTs and municipal contracts specify a minimum reflective grade. If no grade is specified, HIP meets the MUTCD minimum for most applications. For high-speed or nighttime work zones, Diamond Grade DG3 or Diamond Grade Fluorescent Orange provides better visibility and a longer service life.