The History and Evolution of Traffic Drums (Traffic Barrels)

Traffic drums – also referred to as traffic barrels – are familiar fixtures in highway work zones. Often made of bright orange plastic with reflective white stripes, these channelizing devices help direct vehicles around construction areas and hazards. According to the Manual on Uniform Traffic Control Devices (MUTCD), traffic drums are highly visible, command respect from drivers, and serve a critical safety function by alerting motorists to changing road conditions.

Overview of Traffic Drums

Standing about waist-high or taller, modern traffic drums are hard to miss, thanks to their bright orange color and large, retroreflective stripes. Most models also feature a built-in handle on top, allowing easy relocation and also creating a spot for the attachment of flashing warning lights for night use. Their size and robust appearance force drivers to pay attention – a vital element in work zone safety.

Early Origins: From Simple Barrels to Purpose-Built Drums

Before purpose-built traffic drums existed, road crews marked work zones using wooden sawhorses, lanterns, and (later) traffic cones. While these earlier markers offered some visibility, they also had significant drawbacks: cones blew over easily, lanterns weren’t always bright enough, and wooden barriers were cumbersome. A major innovation arrived in 1970 when Charles D. Scanlon – already known for inventing the rubber traffic cone in the 1940s – unveiled the first dedicated traffic barrel. Early versions frequently involved repurposing steel drums painted in orange and white stripes. Although these steel barrels improved visibility and could be weighted for stability, they introduced new hazards. Filled drums were extremely heavy and could cause severe damage if struck by a vehicle. Over time, rust and dents also reduced their effectiveness and visibility.

Evolution in Design: From Steel to Plastic

By the late 1970s and early 1980s, manufacturers began experimenting with lightweight plastic barrels. Plastic could flex on impact, reducing damage to vehicles, and was far less prone to weather-related wear. The first plastic designs were two-piece units often stabilized with sandbags. These prototypes proved far easier to transport and set up than their steel counterparts. In the early 1990s, plastic traffic drums quickly replaced steel barrels across the United States. The 3rd Revision of the 1988 MUTCD (published in 1993) even banned metal traffic drums altogether. Innovations continued, such as incorporating a rubber tire base (often made from recycled tires) to keep the barrel from tipping in high winds without requiring heavy sand or water as ballast. Modern examples showcased robust polyethylene construction, top handles for easy moving, and low-center-of-gravity designs that resist tipping. Today’s plastic barrels are typically made of UV-resistant polyethylene and can be stacked for efficient transport. Many include molded-in hardware or handles so that flashing warning lights can be attached on top for nighttime visibility.

Role in Modern Road Safety

Traffic barrels (drums) are now a mainstay in virtually every U.S. highway work zone. They help:

• Channel vehicles away from construction areas or active lanes.
• Provide visual cues that prompt drivers to slow down, especially in high-speed zones.
• Create modular barriers that can be set up quickly and rearranged as needed.

Many drivers humorously note that some regions experience only two seasons: winter and “orange barrel” season. While it might be an inside joke, it reflects how prevalent these safety devices are during warmer months when road repairs and construction ramp up. According to industry estimates, up to 750,000 barrels are manufactured each year in the U.S. alone, signifying a large market that underscores the vital nature of road safety.

Best Practices for Using Traffic Drums

To ensure effective deployment of traffic drums, agencies and contractors often follow guidelines set forth by the MUTCD, which include:

• Proper Spacing: Drums should be placed close enough so that drivers cannot easily stray between them, yet far enough to guide traffic smoothly.
• Secure Ballast: Use only approved ballasting methods (e.g., weighted bases).
• Consistent Reflectivity: All drums in a work zone ideally should have matching or compatible reflective properties to ensure uniform visibility.
• Regular Inspection: Periodically check drums for damage, dirt, or faded reflectivity, replacing units as needed to maintain safety.

These best practices are critical to upholding both federal and state-level standards, particularly when it comes to high-speed roadways where visibility and stability are paramount.

Reflective Sheeting Levels and Standards

One of the most important features of traffic drums is their retroreflective striping. The Federal Highway Administration (FHWA) requires that any channelizing device used at night be clearly visible to motorists. Common types of reflective sheeting include:

• Engineer Grade Drums (Type I): Basic enclosed-bead sheeting with limited nighttime brightness. Suitable for low-speed areas or daytime-only projects.
• High-Intensity Prismatic Drums (Type III/IV): Mid-range reflective sheeting that is 2–3 times brighter than Engineer Grade, visible up to 1,000 feet under headlights, making it ideal for most highway applications.
• Diamond Grade Drums (Type VI, VIII, or IX): Premium microprismatic sheeting capable of being 10× brighter than Engineer Grade. Often used in high-speed or long-term projects where maximum visibility is needed.

Over time, many state and local agencies have moved toward specifying High-Intensity Prismatic or better to enhance driver safety, especially at night. The bright white stripes on a Diamond Grade drum can often be seen from well over 1,000 feet away, allowing drivers to adjust in advance.

Where to Buy High-Quality Traffic Drums

When choosing traffic drums for highway or construction projects, it’s crucial to look for products that meet MUTCD specifications and have undergone official crash testing, such as NCHRP 350 or MASH approvals. TrafficSafetyStore.com offers a wide selection of MUTCD-compliant, durable traffic barrels with various reflective sheeting options to meet different project requirements. Ensuring you select the right grade of reflectivity and base weight can significantly improve safety and reduce liability in work zones.

Summary

From their humble beginnings as painted steel drums to today’s lightweight, impact-resistant plastic designs, traffic drums have revolutionized work zone safety. Their visibility, ease of deployment, and ability to guide drivers effectively make them an essential tool for any construction or maintenance operation. As innovations in design and materials continue, traffic drums will remain a cornerstone of road safety measures, helping reduce accidents and protect both motorists and workers.

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Additional Resources & References

• Manual on Uniform Traffic Control Devices (MUTCD)
• Federal Highway Administration (FHWA)
• TrafficSafetyStore.com – Traffic Barrels
• NCHRP 350 / MASH guidelines on crashworthiness of roadside safety devices

These references offer further insight into the evolution of traffic control devices and the regulatory frameworks that govern their design and usage. By following these guidelines and selecting high-quality equipment, contractors and agencies can ensure safer roads for everyone.  

Disclaimer: This article is for general informational purposes only. Please understand and follow local laws and specific state regulations