ohio 05 2016

By Irwin RapoportCEG CORRESPONDENT

Sunesis Construction startedwork on the $31.7 million LakeWhite Dam Rehabilitation andRoadway Improvement Project,the reconstruction of 1 mi. (1.6km) of State Route 104 (SR 104)that sits atop the dam, last August.The project, within the Lake WhiteState Park (in Pike County), shouldbe completed this November.

This is a joint venture of theOhio Department of NaturalResources (ODNR) and the OhioDepartment of Transportation(ODOT), with the funding coveredby the state.

ODNR is reconstructing thedam (built in 1935) and makinglong-term risk reduction improve-ments to the 4,200-ft. (1,280 m)earthen dam to meet regulatoryand safety requirements. Thechanges are needed prior to restor-ing the lake level to its normalpool, and crews are replacing theexisting bridge over the spillwayon SR 104. It also includesimprovements to the dam to ensureregulatory and safety require-ments; reinforcing the west bank ofSR 104; completing the lake drain;armoring the upstream face of thedam with riprap and relocating aportion of Crooked Creek; improv-ing the durability of the LakeWhite Dam by armoring the down-stream face with RollerCompacted Concrete to help pro-tect the dam from impacts of flood-ing; and improvements to otheradjacent roadways and replacingthe existing bridge over Pee PeeCreek (also over Lake WhiteSpillway).

ODOT is replacing the existingbridge on SR 104, reconstructing

the highway (1 mi., one lane per-direction) by widening SR 104,constructing turn lanes at SR 551and SR 552, and improving theintersection of SR 104 and CountyRoad 105 (Forest Hills Road).

The traffic management plan issimple as both SR 104 and SR 551are now closed for approximately10 months, and SR 552 and CR105 also will be subject to closureduring the project.

Sunesis crews are workingthroughout the winter to meet thecompletion schedule.

“Since work began,” said

Kathleen Fuller, ODOT’s publicinformation officer, District 9,“crews from Sunesis have beenbusy with the relocation ofCrooked Creek and construction ofa coffer dam that will be used aspart of the lake drain component ofthe project, as well as reconstruc-tion of the boat ramp and dock nearthe Lake White park office off SR551. The next major step is thebridge replacement on SR 104,which is currently under way.”

She said that every effort isbeing made to minimize the impact

ODOT, ODNR Work to Improve Safety of Lake White Dam

OHIO STATE EDITION A Supplement to:

Your Ohio Connection: Ed Bryden, Strongsville, OH • 1-800-810-7640

“The Nation’s Best Read Construction Newspaper… Founded in 1957.”

February 272016

Vol. XVIII • No. 5

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Sunesis Construction photoSunesis Construction started work on the $31.7 million Lake White Dam Rehabilitation and Roadway Improvement Project, the recon-struction of 1 mi. (1.6 km) of state Route 104 (SR 104) that sits atop the dam, last August.

“Since work began, crews from Sunesis havebeen busy with the relocation of Crooked Creekand construction of a coffer dam that will be usedas part of the lake drain component of the project, as well as reconstruction of the boatramp and dock near the Lake White park officeoff SR 551.”

Kathleen FullerSunesis

• February 27, 2016 • www.constructionequipmentguide.com • Ohio State Supplement • Construction Equipment Guide

Due to Age, Condition, Crews Need to Replace Bridge of the work for businesses, agricul-tural activity, and recreational usersof the park. Monthly projectupdates and additional dam riskreduction information is beingposted online at www.engineer-ing.ohiodnr.gov.

“As this project has been insome form of development for thelast few years, the residents andlocal community from the LakeWhite area and nearby Waverlyhave been aware of it and its needsince discussions began, and theyhave been very supportive,” saidFuller. “They understand theimportance of this project for thepreservation of not only the statehighway system, but also the lake,so the overall response to the workthat is being done has been posi-tive. The community is pleasedwith the cooperation and the inter-agency effort to improve the infra-structure while simultaneouslypreserving the environment.

“Obviously, closing a route thatis a principal artery for residential,commercial and tourist traffic to apopular state park creates a signifi-cant impact to everyone,” she said,“so this has been another concernfor those who are affected.However, we have a viable trafficplan in place that is working. Thereis a thru-traffic route, as well as alocal detour that provide an effi-cient means by which motoristscan travel. Also, we have a made afew minor adjustments at the pointof closure at SR 104 and SR 552,in which the contractors haverealigned the junction of theseroutes for a two-way continuouslane for north and southbound traf-fic. This change provides a moreefficient, safer and easier trafficmovement for local traffic to theLake White community.”

Vaughn Wilson, P.E. deputydirector of District 9, said it madesense for both departments to com-bine their efforts and resources.

“Age and deterioration led tosafety deficiencies that included asignificant seepage event at thebase of the dam and spillway inAugust 2014,” he said. “Thisrequired an emergency responseand temporary repairs. The short-term dam risk reduction measureslast year included a partial lower-

ing of the 400-acre lake to a levelthat is approximately eight to 11feet below winter pool. The low-ered lake level is a standard riskreduction measure that reduces thelikelihood of seepage through thedam. Long-term improvements areneeded for this structure to meetdam safety requirements.”

The project for the dam, one ofthe oldest in the state, has been inthe planning and design stage since2008. However, this particularproject, which combines both thedam reconstruction and roadwayimprovements, was in activedesign beginning in 2011.

“This project is a partnershipbetween ODOT and ODNR for thedesign, construction and construc-tion inspection,” said Wilson, “andODOT will manage the shareddam risk reduction and roadwayimprovement projects. The typicallifespan of a bridge of this nature(size, structure type) is, on average,75 to 100 years. This particularbridge was built in 1935, and amajor rehabilitation was undertak-en in 1974. Given its age, currentcondition and factors related to thedam reconstruction, the bridge is inneed of a full replacement. Alongwith the bridge replacement andresurfacing, though, is the recon-struction of the intersections withstate routes 551 and 552. Byadding turn lanes at these loca-tions, we will be improving accessto the state park and the LakeWhite community for visitors andresidents alike.”

The design consultant for thisproject is Stantec ConsultingServices.

The Web page for the projectnotes that the dam’s deficiencieswere documented in recent engi-neering investigations and OhioDam Safety Program inspectionreports.

“Some examples of the defi-ciencies include insufficient stor-age and discharge capacity.Seepage and instability concerns atthe concrete spillway and along theearthen embankment, and [an]inoperable lake drain. The LakeWhite Dam has a Class I potentialhigh hazard rating, meaning a cat-astrophic failure could cause lossof life,” according to the Web site.

Rob Doyle, Sunesis’s director of

operations, also is serving as theproject manager. The armor pro-tection being installed will protectthe dam from washing out in thecase of a future over-topping event.

The lakeside of the dam will geta rip rap armor facing for waveprotection and the top side andentire backside of the dam will getroller compacted concrete (RCC)armoring.

“The lake has been partiallydrained — low enough to maintainthe fish in the lake,” said Doyle.“We dropped the water level by 15feet below winter pool. We plan toinstall the armor around April 1and that should take about sixmonths.”

Preventing debris from fallinginto the water is a key priority forSunesis and ODNR.

“The Rip Rap excavation willbe dug down in,” said Doyle, “sowe have erosion control measuresright along the lake along our exca-vation. It will be placed on geofab-ric, so there will be no contamina-tion.”

Extensive pre-planning andongoing dialogue with ODOT andODNR is ensuring that potentialproblems have been identified andsolutions have been found, and thatunexpected problems are dealtwith rapidly to remain on schedule.

“It’s a team effort and partner-ship,” said Doyle.

The armoring does not requireany adhesive. The roller compact-ed concrete is installed in two-footthick layers using a stair stepmethod.

“At times it can be easy toinstall,” said Doyle. “It’s verysophisticated and it has to be doneas if it is a well-oiled machine — ifnot, it can get away from youbecause the workability time forthe RCC is short. Gears Inc., a sub-contractor out of ColoradoSprings, is manufacturing the RCCon site with its Pug mill. This is themost expensive piece of the workon the project and we’ll be usingover 100,000 cubic yards of it.”

Sunesis has worked on manydam projects and its personnelhave the experience to completesuch operations safely and effi-ciently.

“You have to be well prepared

ODNR is reconstructing the dam (built in 1935) and making long-term risk reduction improvements to the 4,200-ft. (1,280 m) earth-en dam to meet regulatory and safety requirements.

“The Rip Rap excavation will be dug downin, so we have erosion control measuresright along the lake along our excavation.It will be placed on geofabric, so there willbe no contamination.”

Rob DoyleSunesis

see SUNESIS page 6

SUNESIS from page 1

Construction Equipment Guide • Ohio State Supplement • www.constructionequipmentguide.com • February 27, 2016 •

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46th Annual Power Show Showcases Latest Equipment

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(L-R): Rich Durst, Jeff Richards andJason Crain, all of Columbus EquipmentCompany, speak with attendees aboutthe company’s lineup of Komatsu, Kubotaand Takeuchi equipment at the show.

Bob Candee (L) of Fecon joins Gabe Clark and Tony Little at theCompany Wrench equipment display to talk about the dealershipslineup of equipment.

JJ Sutphin stands ready to answer questionsabout the Multi One articulated compact loaderat the Buckeye Equipment Sales display.

(L-R): Linda Kahler, Marti Smith, Jenny Archibald,Dennis Alford, Dave Kahler, all of OMEDA and KimRominger, OMEDA executive vice president/CEO, kepteverything running smoothly at the 2016 Power Show.

Keith Darding stands at the Gravely dis-play.

The 46th Annual Power Show Ohio was held on Jan. 28 to 30at the Ohio Expo Center in Columbus, Ohio. Sponsored bythe Ohio-Michigan Equipment Dealers Association, the

event offers Ohio’s agricultural, landscaping, grounds mainte-nance and construction industry professionals an opportunity toattend educational seminars and see the latest equipment, productsand services. This year approximately 200 dealers, manufacturersand product and service providers filled more than 200,000 sq. ft.(18,580 sq m) of exhibit space in the Ohio Expo Center’s BrickerBuilding & Celeste Center.

Educational seminars and presentations were conducted hourlystarting at 10:00 a.m. in the Celeste Center throughout the three-day event. Sessions covered a range of subjects including equip-ment safety issues, crop production, online marketing tips andstrategies for developing a succession plan to ensure family reten-tion of farm operations.

With its origin as the Buckeye Implement Dealers Associationand dating back more than 120 years, the Ohio-MichiganEquipment Dealers Association is one of the oldest organizationsof its kind.

The non-profit association serves and promotes the interests ofpower equipment dealers in Ohio and Michigan.

(This story also can be found on Construction EquipmentGuide’s Web site at www.constructionequipmentguide.com.)CEG


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and well planned out because one bad day will adverselyaffect your operation,” said Doyle. “The armor installationand overall work is repetitive, so we never switch up ourguys. When you get into a good routine, that’s where youmake your best production. Everyone knows the drill andcommunication is important to address problems that ariseand keep the flow going.”

In the meantime, work is progressing on the installation ofthe new drainage structure, along with piping, for the lake. Acoffer dam is being constructed in the middle of the lake thatis using 72 ft. (21.9 m) long sheet piling that reach down to

the bedrock.“The coffer dam travels all the way from the lake through

the dam,” said Doyle. “We have to open up the dam to installthe lake drain piping. We’ve also had a couple of diversbecause we have a siphon system that drains the lake andthey have to do maintenance on the siphons if debris getswrapped around the intake. We’re not using any barges as wehave built work pads to access everything.

“This is a sophisticated operation,” he said. “We haverelocated the creek that flowed into the downstream side ofthe dam where the spillway comes through. It was approxi-mately 50,000 cubic yards of excavation. We also demol-

ished the bridge on SR 104 overtop the spillway and are inthe process of rebuilding it; and we’re also installing a retain-ing wall on the backside of the dam that is approximately300 feet long, which is driven sheet piling that gets encapsu-lated with concrete.”

Ice is not a major problem for the crews — it is the waterlevels that are a constant concern.

“The water fluctuates so much in both the lake and on thebackside of the dam as the spillway drains into a creek whichis fed by a river,” said Doyle, “and we still have all thedrainage area coming into the lake. At this time of year, if weget a two-inch rain or more, it will bring the lake up by 10 or12 feet in matter of four to five hours. To deal with this con-tingency, we have seven 18-inch siphons that siphon thewater out of the lake through gravity.”

The asphalt-paved road will be replaced with a 9-in. (22.8cm) thick concrete pavement, one that should have a lifespanof 50 plus years, after the armoring work is completed.

When all the work is done, Sunesis will have removed202,000 cu. yds. (154,440 cu m) of rock and earth and willbe installing in its place 100,000 cu. yds. (76,455 cu m) ofRCC, 16,500 cu. yds. (12,615 cu m) of concrete, 2,000 tons(1,814 t) of steel and rebar, and 2,300 tons (2,086 t) ofasphalt.

The amount of new materials to be used is still beingdetermined.

The day shifts currently have nearly 28 workers fromSunesis and as of April 1, the number will double with thesubcontractors

Sunesis is using two 222 100-ton (90.7 t) Manitowoccrawler cranes that it is renting from Maxim Crane Works inWilder, Ky.; five excavators including a Cat 345, a Cat 330and a Cat 320 and a Kobelco 330 and a Kobelco 210; a CatD6N and a D5 bulldozer; and three Volvo A25 off-roadtrucks, which will soon be bolstered to eight.

The company’s main yard is 90 mi. away, but one of itsfield mechanics lives only 15 mi. from the work site and hevisits it about twice a week to do wear and tear repairs forhoses and tire punctures, as well as routine maintenance andbreakdowns.

Vehicles and equipment are thoroughly inspected prior tobeing shipped to a work site.

Winter conditions have a minimal impact on the equip-ment.

“If it is going to be less than 15 degrees, we typically tendnot to work,” said Doyle, “but the schedule is tight on thisproject and we’ve worked just about every day, except onSundays. When it is 0 degrees outside, everything is fired upand we leave it running for the day. There are no real issues.”

New equipment is purchased from local dealerships inOhio, including Southeastern Equipment Company inMonroe, Ohio CAT in Sharonville and Rudd Equipment,also in Sharonville.

“We also go to auctions in Florida and tri-state auctionsaround here,” said Doyle.

Looking ahead to the armor installation, Doyle said, “Weneed to make it to the spring and not get flooded out. Thewater can come up fast and as long as we have a somewhatdry spring, we should be able to complete the project ontime.”

(This story also can be found on ConstructionEquipment Guide’s Web site at www.constructionequip-mentguide.com.) CEG

Work Progresses on Installation of Drainage StructureSUNESIS from page 2

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Ohio..

‘Buckeye State’ Highway LettingsThe Ohio State Department ofTransportation received bids for transporta-tion-related improvement projects.The following is a list of some of the

projects let.

Project No: 150395Type:Major reconstruction.Location: FRA-IR 71-5.29.State Estimate: $42,100,000Contractors and Bid Amounts:

• Shelly & Sands Inc., Columbus, Ohio— $38,108,261

• Kokosing Construction CompanyInc., Columbus, Ohio — $39,016,707

• John R Jurgensen Company,Cincinnati, Ohio — $39,388,90Completion Date: July 31, 2017

Project No: 150437Type: Two lane resurfacing.Location: PRE-SR 503-12.01.State Estimate: $4,067,000Contractors and Bid Amounts:

• Barrett Paving Materials Inc.,Middletown, Ohio — $3,806,296

• Walls Bros Asphalt Company Inc.,

Greenville, Ohio — $4,139,513Completion Date:Oct. 15, 2016

Project No: 150455Type: Bridge replacement (1 bridge).Location:GUE-CR 347-00.92.State Estimate: $2,145,000Contractors and Bid Amounts:


• Ohio Bridge Corp., Cambridge, Ohio— $2,655,987

• Righter Company Inc., Columbus,Ohio — $2,674,350

• J D Williamson ConstructionCompany Inc., Tallmadge, Ohio —

$2,737,455• George J Igel & Company Inc.,

Columbus, Ohio — $2,877,663• Orders Construction Company Inc., St

Albans, W.Va. — $3,137,962• Ohio-West Virginia Excavating

Company, Shadyside, Ohio — $3,181,564Completion Date: June 1, 2016

Project No: 150396Type:Major reconstruction.Location: FRA-IR 70-3.41.State Estimate: $48,300,000Contractors and Bid Amounts:

• Complete General ConstructionCompany, Columbus, Ohio — $46,951,260



• John R Jurgensen Company,Cincinnati, Ohio — $50,199,713Completion Date:Oct. 1, 2017

Project No: 150448Type: Bridge repair.Location:MOT-IR 75/US 35-

11.74/15.16N.State Estimate: $11,094,000Contractors and Bid Amounts:


• Eagle Bridge Company, Sidney, Ohio— $11,778,118

• Illinois Const. Corp., Elburn, Ill. —$13,992,120

• Great Lakes Construction Company,Hinckley, Ohio — $14,232,521Completion Date: Sept. 30, 2017

Project No: 150451Type: Two lane resurfacing.Location:DEL-SR 3-1.38/5.41 (Part 1 andPart 2).State Estimate: $2,738,000Contractors and Bid Amounts:

• Shelly Company, Thornville, Ohio —$2,859,559


• Shelly & Sands Inc., Columbus, Ohio— $3,015,922Completion Date: Sept. 30, 2016


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