Augusta Sign Company

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Use Wall Letter Signs to Identify Your Space!

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New wall letters provided for Kate Collins Middle School, Waynesboro, VA.

Multiple Choices

During the course of my signage career I have had many opportunities to utilize wall letters for customers. Wall letters are any type of flush or dimensional lettering or graphics painted on or attached to a wall. Generally wall letters are used to promote a brand or identify a particular room or building and can be mounted to both exterior and interior walls.

The most typical letters I have recommended are the dimensional type: Letters cut from acrylic or aluminum using a CNC router; and also letters molded from plastic or various metals including aluminum and bronze. Recently we tackled two jobs utilizing dimensional letters. The first job was an interior project for Fishburne Military School in Waynesboro, VA. The school had ordered several honorary wall plaques and needed us to install them as well as wall lettering over the door to the hall. These letters were flat cut out (FCO) acrylic that were CNC-cut from black pigmented material. We utilized a paper pattern to center the lettering over the doorway then stud-mounted the letters into the wall with silicone adhesive.

Inspecting newly installed wall letters at Fishburne Military School, Waynesboro, VA.

Make Wayfinding Easier

We also helped the Waynesboro City Schools with identifying their gymnasium. Not only does naming school buildings help new students and teachers get around easier, it also helps visitors, vendors, and most importantly, first-responders find their way quickly when the time comes. On this particular project, we suggested formed plastic letters

Wall letter installations typically begin with a paper pattern, shown here taped to the wall and ready for hole preparation.

to match other entrance lettering. Once again we started the installation process by making a paper pattern, centering it over the entrance and then marking and drilling holes for the stud-mounted letters. The background wall in this case was constructed of EIFS so there wasn’t much to drill out for the holes. Again we used architectural grade clear silicone for the adhesive to secure the studs.

If you need any help with wall letters at your business, industrial plant, school, or church just reach out anytime!!

Mark Hackley is president of Augusta Sign Company based in Augusta County, VA. He can be reached at 540-943-9818

Trouble-Free Main Entry Signs Becoming Our Specialty

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“The sign looks great! I appreciate the trouble free install. We’ve heard several compliments both from staff and clients,” Bryan Beamer, DVM

The new entrance sign in Culpeper completed in April 2021.

“GO-TO” SIGN DESIGN

Trouble-free main entry signs are becoming our specialty go-to sign design option for many businesses. These signs are very simple, constructed of two upright aluminum posts with horizontal cross beams on which we mount the main sign panels. We have used them for a variety of business marketing applications for churches, apartment complexes, office parks, and medical facilities, but see endless applications in our market area of Virginia.

New church entrance sign installed in Staunton in November, 2020.

ECONOMICAL CHOICE

If a customer has a budget under about $5,000 and needs a long-lasting, low-maintenance exterior identification sign, then this is a great option to consider. We have provided many one-sided options for less than $3,500 which includes: design, manufacture, and installation. The customer can choose to illuminate the signs at a later date or leave them un-lit. Many of the times, the customer will construct nice landscaping beds or planters below the signs to dress them up and protect them from lawncare equipment.

Apartment entrance sign placed into service in September, 2019.

SIMPLE YET EASILY CUSTOMIZED

The beauty of these main entrance signs is their simplicity and opportunity for customization. We have attached aluminum compostite (ACM) panels to them, as well as sandblasted and carved cedar panels. All three materials make for long-lasting minimal-maintenance signage. We use 1/4″ thick ACM panels and dress them with printed 3M vinyl film which generally lasts 5-10 years before the weather begins to degrade the sign’s coloring and overall appearance. When the signs fade, they are easily replaced or recovered for another 5-10 years of service. The post and frame system is finished with a durable powder-coat finish and will last many years before required maintenance.

Constructing an office park directory sign out in the workshop in November, 2020.

TURN-KEY PRODUCT

Customers who choose cedar panels for the signs can expect a similar 5-10 maintenance period, but the actual cedar boards will last a lifetime as they are naturally insect and rot resistant. Augusta Sign Company can offer turnkey service for a company’s main entrance sign offering permitting services, manufacture, installation, and periodic maintenance and replacement services.

Contact Mark Hackley at 540-943-9818 for more information.

Updating an Office Park’s Street Appeal

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Updating an office park’s street appeal is not something I do everyday.

Since I’m a one-man sign shop, I’m usually bouncing around working on a variety of projects like a ping pong ball. But since several of my customers operate in the commercial or residential real estate sectors —some as developers, some as property managers— I occasionally have an apartment complex, subdivision, office complex, industrial park, healthcare center, etc. to work on.

AFTER-The completed updated office directory sign at Stoneridge.

One of these clients, Property Management of Virginia, approached me early on in 2020 to update a directory sign at Stoneridge Office Park in Waynesboro. The existing directory sign had been in place for decades and needed work. After surveying their site I recommended a complete replacement of the sign panels and structural posts on the dated directory, and also a repaint for their entrance sign at the main entrance. I figured since 20,000-plus vehicles pass their entrance sign every day, it should always look its best!

BEFORE-The old directory as it looked before the renovation process.

The old, deteriorated directory sign was installed on two rusted steel poles imbedded in the concrete core of a brick base that was about 6 feet wide. At first I considered refurbishing the steel posts and using them as the support for the upgraded directory panels. After much thought and discussion with

One of the rusty uprights we replaced with maintenance-free aluminum posts.

one of my architectural sign component suppliers, I chose to replace them with two end-mounted aluminum posts, a much more maintenance-free solution for my customer. Also, by moving the posts outward I was able to increase the mass of the sign leaving more room for branding the “Stoneridge” name at the top.

The previous main sign did not reflect a positive street-side image and needed some work.

The faded, peeling and cracking road sign needed to be re-set and reinforced within the existing stone wall and then repainted. We removed the routed aluminum face and transported it to the shop where we removed the existing finish, primed, and repainted the sign with a high quality industrial enamel supplied by Burk’s Paint and Wallpaper in Waynesboro. We took advantage of good fall weather to re-install the main sign panel, then went right to work on building the new directory.

The updated main entrance sign on Route 250 West, Waynesboro, VA.

The posts and crossbeams were custom-made to fit into the sides of the existing brick foundation. Made from aluminum with a powder-coat finish, the posts are maintenance-free and provide a strong platform for the

Making the 60 individual tenant panels in the shop.

two fairly heavy directory panels. We cut the two large round-top sign panels and smaller individual tenant panels in the shop and applied printed 3M vinyl for the background color and graphics. There were a total of thirty changeable tenant signs per side, attached with stainless steel fasteners which can be easily changed as tenants come and go.

Fabricating the directory sign on the shop table.

All in all the project improved the look of the office park, but there’s room for improving many of the other signs in the complex. Perhaps that will be in our project pipeline for 2021!

Putting the final fasteners in the newly renovated main entrance sign.

Mark Hackley owns and operates Augusta Sign Company serving Staunton, Waynesboro, and Augusta County, Virginia…and beyond.

Contact Mark at 540-943-9818 or mark@augustasigncompany.com

Restoring the Billboard for Silver Lake Mill, Dayton, VA

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FRESH LOOK NEEDED

I remember meeting with Cheryl Lyon in my shop sometime early in the spring of 2020 after she sought out my company from a Facebook referral. She laid out across my shop table drawings and photographs of an existing billboard sign in Dayton that had deteriorated and wanted to hire me to upgrade it, sharing her artistic shematics for a new look.

Laying out the ACM panels for the billboard veneers on the shop tables.

The original mill on Silver Lake was built in 1822. It burned in 1856, was rebuilt, and was burned again during the Civil War in 1864. It was last operated as a mill by Rockingham Milling Co., which ceased operations around 1990 after constructing a new facility near Harrisonburg.

The top ACM panel cut to shape on shop table.

HISTORY RESTORED

Lyon, a member of the board of the Harrisonburg-Rockingham Historical Society, heard the mill was up for sale and thought it would be an awesome building for her growing specialty glass ornament business and purchased it around 1999. Soon afterwards she had an advertising sign erected by another firm to direct local customers to her business, which was a distance off the main road, Route 42. In order to erect an off-premise sign she had to coordinate construction of the sign with the Virginia Department of Transportation (VDOT) as well as the Town of Dayton and Rockingham County.

The primed aluminum ball finials waiting for the 23K gold.

After years of wear, the original sign lost its luster, hence her trip to my shop for fresh ideas. When Cheryl first approached me I was just finishing a custom church sign in Bridgewater and getting ready to start a huge job for the Blue Ridge Tunnel on Afton Mountain. I suggested she get in touch with me in June.

Inspecting the 3M digital print on the shop floor prior to application to ACM.
Loading up the trailer on installation day!

JOINT PROJECT

When June rolled in, Cheryl and I were able to complete the sign design work and applicable permitting via emails. I used help from Lisa Brady, a free-lance artist and graphic designer in Bath County, to provide several design concepts. Cheryl took care of the permit research. I always like it when customers secure their own sign permits. Especially in this case where so many agencies are involved in the permitting process. I was able to help with the cost worksheet needed by VDOT and also coordinated inspections with Rockingham County, but Cheryl did all the heavy legwork.

Doug Sheffer helping me with the installation; shown trimming one of the posts to fit grade.

Finally, in October, Cheryl was ready to pull the trigger on making a sign purchase. Once I received her deposit, I quickly ordered materials and began to fabricate the new sign. We took advantage of great weather, disassembled the old sign, and dug the 24 inch diameter by 4-foot deep holes for the new posts. We covered the holes with plywood covers and returned the next day to set the posts while finishing the sign in the shop.

Plumbing the posts and getting ready to install the new billboard sign panels.

TALKING SHOP

We laminated new 3mm thick Aluminum Composite Material (ACM) panels to the existing boards. Then we applied digitally printed 3M vinyl graphics to the ACM on one side and reinforced the joint between boards across the back. We fastened refurbished steel angles to the new 4 X6 X 15-feet long treated posts, and loaded up the trailer.

Doug attaching the 23K gold leaf finials.

Upon reaching the jobsite on the third trip, we hoisted the large 7-feet high X 7-feet wide sign up and between the posts, and fastened them securely. To finish it off, we attached the two 23K gold leaf ball finials to the top of each post and hung a separate directional arrow sign from the bottom of the main billboard.

The sign now up, but braced until the concrete cures. We used about a ton of gravel and concrete to pour the two footers. I think this sign will be around for a while!

On the fourth trip after a week’s time to let the concrete footers cure, we dismantled the bracing and touched up the posts.

NOT A RUN OF THE MILL PROJECT

The finished product!

All in all it was a very fun and interesting project and awesome weather to work in. I truly appreciated the chance to play a part in directing the public to the historic mill! It is reminiscent of the Savage Mill in Savage, Maryland, located about 5 miles north from where I grew up. That was also an old mill turned into a glass ball ornament factory before later becoming an artisan center. The reason I am familiar with it is because my Grandpa Hackley used to work in the original cotton mill before it too became an ornament business. He made Christmas balls there up until his death at age 79. Grandpa died instantly from a heart attack at the Savage Mill in 1964!

I hope I will go that way…while doing something I enjoy most…making signs!

Mark Hackley owns Augusta Sign Company, Staunton, VA

I’ve Been Working On The Railroad

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www.augustasigncompany.com-Crozet-Afton-Blueridge-Tunnel-Cedar-Signs
Mark Hackley, owner of Augusta Sign Company, poses next to the east trailhead kiosk in Nelson County, Virginia.

TUNNEL VISION

I wonder if Claudius Crozet, the engineer posed with a technically-challenging project in 1849 to bore a mile-long hole through a Virginia mountain to help open the railroad to the American West, doubted his abilities to complete the project successfully? Even though years earlier he had triumphantly completed other great nineteenth century civil engineering projects, like his once state-of-the-art 230-mile Staunton-Parkersburg Turnpike, I ponder whether he ever doubted his abilities for such great achievements?

I wonder if the complexity and risks of each new custom project weighed heavily on his brilliant mind? If it did, he worked through it all! Soon I would get the chance to work through a challenging project of my own: building the signage system for Crozet’s world-famous tunnel.

Both Crozet’s tunnel and the mountainous toll road built from 1831-1850 became crucial transportation lines in the American Civil War. Maybe my signs could help future generations remember Claudius and his amazing public works projects.

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Doug Sheffer in the shop gluing up cedar boards for the tunnel signs.

OPPORTUNITY BLOWS HER HORN

Abandoned for many years, the tunnel laid eerily void of activity alongside the updated tunnel which took its place in 1944 until chatter about restoration began in 2001 when Nelson County planners saw potential as a public greenway and rail trail. In the summer of 2019 I was presented the opportunity to bid on fabricating signage for Crozet’s landmark tunnel for Fielder’s Choice Enterprises (FCE), Inc., one of the Caton Companies, via referrals from two former friends in the industry who were now retired and looking after me!

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Marshall Carpenter sanding freshly glued cedar panels for the Blue Ridge Tunnel.

Initially, I was positive that I could handle the scope of work which included providing two large wood entry signs, two large wood informational kiosks, four interpretive signs, and various traffic signs, safety signs, and bollards. But after over-thinking it all, I hesitated to respond and filed the opportunity in a stack of other potential projects until early 2020.

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Carved cedar signs ready for primer and paint.

PANDEMIC RELIEF

My company’s work-in-progress list was shortening in December, 2019, so I contacted Mark Zimmerman, project manager with FCE to see if he was still interested in signage quotes for the tunnel job. After finding out he had yet to make a decision on the signs, I asked my wife if I should tackle such a large-scale job considering that I am usually a one-man operation, and this would require help.

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Applying bulletin enamel to the incised lettering.

Understanding previous successes tackling similar projects since the 1990’s, she very encouragingly helped me decide to give it a shot. So just weeks before the COVID-19 pandemic hit the country, I bid the job and was soon awarded the contract to build all the signage for the third and final phase of the Blue Ridge Tunnel restoration on Afton Mountain! What a blessing this project soon became as my usual education and hospitality customers put upcoming orders on hold as the COVID crisis crept in!

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Assembling the kiosk panels in the shop. We used Pannier Gel Coat Laminate (GCL) panels for the maps.

HUGE CHALLENGE AHEAD

I spent a full week designing the detailed shop drawings which showed FCE, Nelson County, and Woolpert, Inc., the A&E firm who designed the overall tunnel renovation project, exactly what I would be providing. Once these were approved, I ordered the materials for the project.

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Scott Flavin lifts a boulder from one of the holes for an interpretive sign. The soil on the mountain was extremely rocky and the gas powered post hole digger was rendered useless!

Obtaining western red cedar boards from northwestern Canada during a pandemic where international borders were closed was a huge challenge. Everyone was out of stock, or only had a few boards left of the quality required. To get my hands on enough clear, all-heart vertical grain material, I had to piece together shipments from three different distributors across the US to get what I needed.

I had to construct four large three-inch thick cedar panels, even though I am mostly accustomed to working with inch-and-a-half thick material. The two kiosk panels were so large and heavy that I had to design and build them in two sections so they could be successfully delivered and installed. I purchased the treated yellow pine posts from Virginia Frame Builders and secured the paint from Burk’s Paint & Wallcovering, two of my sign customers and quality established Augusta County-based building material suppliers.

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Doug Sheffer inspects a hole for the east kiosk.

HARD WORK PAYS OFF

Augusta Sign Company has successfully operated as a one-man shop since reopening full-time operations in 2015, occasionally utilizing the services of a part-time sub-contractor if needed for installations. I was fortunate to have been able to assemble a great team of installers who assisted me for several weeks in the final stages of installation in June, 2020.

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The install crew working on assembling the east kiosk in Nelson County.

Digging 21 holes, often through gravel beds of an ancient railroad track, was no easy task. I must admit I have never been in better shape since those 3 weeks of extreme manual labor over the summer when we installed all the signage! Eight of the holes had to be almost five feet deep to accomodate the tall 8X8 wood posts. That meant a whole lot of intense digging into a variety of Virginia soils across several miles of terrain, and in 90-100 degree humid Virginia weather.

Participating in this challenging experience provided personal insight into how healthy those nineteenth-century railroad workers must have been after years of manual labor! We just can’t quite get to that level of physical activity in these days of computers and television, but I got a small taste of it, even though I was sometimes able to utilize a mechanical post hole digger. I’m glad I took on the project and I’m very satisfied when seeing the finished signage up there on Afton Mountain.

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Scott and Doug securing the top half of the east kiosk.

The park is currently closed as the contractor finishes up the final touches, and the east and west entry signs are currently covered in tarps. Soon the park will begin to open and the tarps will come down. I hope many people will enjoy my labors of 2020 and visit the park for many years to come… even after I’m dead and gone!

I hope you visit this unique part of Virginia’s history. My wife and I can’t wait to ride our bikes through the tunnel…as long as we have a set of strong batteries in our headlamps to make it through!!

HERE IS A LINK TO A TUNNEL CONSTRUCTION REPORT BY NELSON COUNTY PARKS AND RECREATION THAT FEATURES OUR SIGNAGE: https://www.vaco.org/wp-content/uploads/2021/07/NelsonCountyBlueRidgeTunnelRehabTrailProject.pdf

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Mark smiling after the last sign for the project was installed in late October, 2020.

Mark Hackley is owner of Augusta Sign Company.    540-943-9818