The Rise of and Future of Traffic Cones

TSS Customer ServiceMay 26, 2025May 26, 2025Work-Zone, Traffic Safety, Resource Guide

The Complete History of Traffic Cones in America

Where did Traffic Cones come from and now that they are “everywhere” what does their future hold?

Bright orange traffic cones are a familiar sight on American roads, in fact they seem like they are everywhere, guiding drivers through construction zones, job-sites, and parking areas, ensuring worker safety. But how did these simple devices become indispensable? At Traffic Safety Store, we’re diving into their 80-year journey—from a street painter’s vision in 1943 to upcoming future IoT-enabled smart technology—exploring the innovations, regulations, and cultural impact that made traffic cones a universal safety icon.

1. Before the Cone: Early Traffic Control Challenges

In the early 20th century, as automobiles transformed American transportation, road safety lagged behind. Construction zones relied on cumbersome and hazardous traffic control methods that endangered workers and drivers alike.

Early Traffic Control Methods:
Wooden sawhorses: Bulky, immobile, and destructive in collisions.
Iron tripods: Lethal in crashes, often causing severe injuries.
Kerosene lanterns: Dim, fire-prone, and ineffective in daylight.
Flag bearers: Risky, labor-intensive, and limited to daytime.

The Federal Highway Act of 1921, which funded the first national highway system, exposed the urgent need for safer, portable traffic control solutions as road construction surged. Today, modern traffic safety products have revolutionized work zone protection.

2. Pioneering Efforts: Traffic Cone Precursors (1910-1940)

Starting in 1914

Concrete Conical Markers

New York City tested heavy concrete cones, which, despite their promising shape, were impractical due to their 50-pound weight and immobility.

During the 1920s

Metal Cone Trials

Lightweight metal cones were tested but abandoned due to their danger in collisions and frequent theft for scrap metal.

Into the 1930s

Rubber Pylon Prototypes

Early rubber pylons offered flexibility and self-righting features but were cost-prohibitive, limiting widespread adoption.

These experiments laid the groundwork for a breakthrough, as innovators sought a device that balanced safety, affordability, and practicality.

3. A Game-Changing Invention: Scanlon’s 1943 Patent

“I needed a way to stop drivers from ruining my paint lines while keeping everyone safe. That’s when the idea for the cone was born.” — Charles D. Scanlon, Inventor

Charles D. Scanlon, a Los Angeles street painter, grew frustrated with drivers disrupting his freshly painted road lines. His solution—a lightweight, flexible, and highly visible traffic cone—revolutionized road safety.

Scanlon’s Design Innovations:
Hollow structure: Lightweight yet stable with added weight.
Flexible materials: Bent on impact, reducing damage.
Self-righting: Returned upright automatically.
Bright colors: Enhanced visibility day and night.

On November 2, 1943, Scanlon’s U.S. Patent 2,333,273 for the “safety marker” was granted, establishing the blueprint for the modern traffic cone, now a staple in our traffic cone inventory.

4. The Interstate Boom: Cones Go Mainstream (1950s-1970s)

The 1956 Federal-Aid Highway Act sparked a construction boom, creating 41,000 miles of interstate highways and driving demand for efficient traffic control solutions.

Factors Fueling Adoption

Cost Savings: Rubber cones were 75% cheaper than wooden barriers.
Efficiency: One worker could deploy 50 cones faster than 10 barricades.
Safety Gains: Flexible cones cut collision severity by 60%.
Regulation: The MUTCD standardized cone specs in 1959.

1959 Milestone: Pacific Gas & Electric mandated traffic cones around all service vehicles, inspiring utilities nationwide to follow suit.

5. Material Advancements: From Rubber to Smart Polymers

Traffic cone materials have evolved alongside polymer science, balancing durability, visibility, and sustainability. Explore our range of MUTCD-compliant traffic cones built with these modern materials.

Era	Material	Advantages	Limitations	Breakthrough
1940s-50s	Vulcanized Rubber	Self-righting, durable	Heavy (8-12 lbs), costly	First flexible device
1960s-70s	PVC Plastics	Light (3-5 lbs), weatherproof	Brittle in cold, UV fading	Mass production
1980s	LDPE	UV-stable, vibrant colors	Limited temperature range	Integrated color
1990s	HDPE with Reflective Bands	Night visibility, modular	Complex assembly	Retroreflective tech
2000s	Recycled Polymers	Sustainable, cost-effective	Quality variability	Collapsible designs
2010s-Present	Fluorescent Polymers	Daytime visibility, IoT-ready	Higher cost	Smart sensors, LEDs

6. The Digital Era: Upcomng Smart Cones and IoT Integration

Smart traffic cones could potentially transform work zones with IoT technology, enhancing safety and efficiency. Check out some ideas for advanced traffic safety solutions that could be a part of the future of traffic safety.

Smart Cones Features in the works

GPS Location Tracking

LTE-M Cellular Connectivity

LED Dynamic Lighting

AI Traffic Analysis

Applications

Deployment Tracking: Ensures accurate placement and retrieval.
Impact Alerts: Notifies crews of collisions or damage.
Weather Adaptation: Adjusts lighting for visibility.
Traffic Insights: Optimizes work zone layouts.
App Integration: Possibly updates navigation apps like Waze.

7. Why Cones Rule: The Perfect Safety Solution

Traffic cones owe their dominance to a unique blend of practicality, regulation, and versatility, making them a cornerstone of our traffic safety product line.

Regulatory Push

MUTCD and OSHA mandates require cones for most temporary traffic control, ensuring consistent use across the U.S.

Economic Advantages

Low Cost: Injection molding dropped prices below $10 per cone.
Easy to Store: Cones can be put away between assignments, nesting makes for efficient storage.
Low Maintenance: Durable with minimal to no upkeep.

Versatile Applications

Beyond roads, cones are used in:

Sports training (e.g., soccer drills).
Warehouse safety zones.
Airport tarmac operations.
Event crowd control.
Emergency response setups.

8. Meeting the Standard: 2023 MUTCD Guidelines

The MUTCD 11th Edition (2023) sets rigorous standards for traffic cones, ensuring safety and consistency nationwide. All our traffic cones meet these standards.

Category	Requirements	Purpose	Testing
Color	Safety orange (Color 12199), orange/white reflective bands	Uniform visibility	Colorimeter testing
Physical	Bend 90° without cracking, self-right in 3s, withstand 35 mph impact	Reduce crash severity	Impact testing
Height	18″ (≤45 mph, day), 28″ (>45 mph or night), 36″ (highways)	Ensure detection	Visibility studies
Retroreflectivity	6″ white band, 4″ orange band, 250 cd/lx/m² (white), 180 cd/lx/m² (orange)	Night visibility	Retroreflectometer
Markings	2″ max ID, no ads, no interference with colors	Maintain credibility	Visual inspection
Stability	Resist 25 mph winds, weighted base, stackable	Prevent debris	Wind tunnel testing
Maintenance	Replace if faded, cracked; clean regularly	Ensure effectiveness	Field inspections
Crashworthiness	NCHRP 350 compliant, no heavy fragments	Minimize hazards	Crash testing

9. Looking Ahead: The Future of Traffic Cones

As autonomous vehicles and smart cities reshape transportation, traffic cones are evolving to meet new challenges.

Emerging Trends

Vehicle-to-Cone Communication: Cones will transmit data to self-driving cars via 5G.
AI Optimization: Machine learning will predict optimal cone placement.
Augmented Reality: AR-enabled cones could project warnings for drivers.
Modular Designs: Cones with interchangeable smart modules for flexibility.

Prediction: By 2030, 25% of U.S. traffic cones will feature IoT capabilities, driven by smart city initiatives and federal funding.

10. Conclusion: A Legacy of Safety and Innovation

From Charles Scanlon’s 1943 patent to futuristic upcoming IoT-enabled smart cones, traffic cones have transformed road safety over eight decades. Their journey reflects advances in materials, technology, and regulations, making them indispensable in construction zones and beyond. At Traffic Safety Store, we’re proud to supply the highest-quality cones to keep America’s roads safe. As we move toward a future of autonomous vehicles and smart cities, traffic cones will continue to innovate, ensuring safety for generations.

Explore Our Traffic Safety Solutions

Need MUTCD-compliant traffic cones or advanced safety devices for your next project? Discover our full range of products designed for work zone safety and efficiency. Shop Traffic Cones Now

About Traffic Safety Store

Traffic Safety Store is America’s trusted source for traffic control devices, offering MUTCD-compliant traffic cones, signs, and smart safety solutions. With decades of expertise, we’re committed to advancing road safety nationwide.