602.01  Description

602.02  Materials

602.03  Construction Requirements

602.04  Method of Measurement

602.05  Basis of Payment


602.01  Description.  This work consists of constructing headwalls, pipe cradles, collars, and other brick and masonry units of the types and sizes specified.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

602.02  Materials.  Furnish materials conforming to:

Backfill......................................................................... 203

Concrete, Class QC-Misc................................. 499 and 511

Water for grout and mortar...................................... 499.02

Reinforcing steel...................................................... 509.02

Cement for mortar.......................... 701.01 through 701.07

Sand for mortar........................................................ 703.03

Granular base ........... Granular material, Type B, 703.16.C

Brick and masonry units................ 704.01, 704.02, 704.03

Nonshrink mortar.................................................... 705.22

Lime for mortar........................................................ 712.04


602.03  Construction Requirements.  Construct the designated items as shown on the plans.

A.      Excavate to dimensions that provide ample room for construction.  Remove obstructions as necessary to perform this work.

Protect the sides of all excavations from caving by providing suitable sheeting, shoring, and bracing.  Use excavation methods that do not disturb the original material below the bottom of footers or below the additional 6 inches (150 mm) required for precast structures.

If the material found at the bottom of the headwall or below the additional 6 inches (150 mm) required for precast structures is not suitable for a foundation, excavate to further depth to provide a suitable foundation. Backfill the void left by the additional excavation with granular base.  The Department will pay for this additional work according to 109.05.

Backfilling shall follow completion of the work as closely as the construction will allow.  Backfill with granular base or soil. Place backfill in 6-inch (150 mm) loose lifts.

B.      Compaction requirements are according to Item 203 except for the following:

Four passes per lift with additional passes as required until 95 percent compaction is reached.  Use compaction equipment with a minimum total weight of, or minimum centrifugal force of, 1 ton (0.9 metric ton).  Supply the manufacturer’s specifications for this equipment to verify these requirements.

C.      Cast-in-place structures are headwalls, pipe cradles, collars, and other units. Construct cast-in-place structures according to the corresponding Standard Construction Drawing using methods specified in Items 499, 511, and 509.

D.      Precast structures are half height headwalls for conduits up to a maximum of 78 inches (1980 mm). These pre-approved precast structure drawings are on file in the Office Material Management. With the submission of the TE-24 from an approved manufacturer furnish stamped, approved from the Office of Hydraulic Engineering design drawing sheets.  Precast half-height headwalls for elliptical and pipe arch conduits may be constructed from templates of the actual conduit being supplied, up to a maximum 78 inch (1980 mm) (round equivalent) to the project to ensure the opening is OD plus one inch.  Submit drawings to the Office of Hydraulic Engineering for approval, on a project by project basis, of precast half-height headwalls for elliptical and pipe arch conduit.  Non-pre-approved drawings are required to be submitted to the Office of Hydraulic Engineering for approval. Allow 4 weeks for approval.  Failure to furnish the stamped, approved design drawing sheets will result in rejection of the precast structure.  The drawings will include the following:

1.      All manufacturers are pre-approved according to Supplement 1073.

2.      All reinforcing steel will be epoxy coated.

3.      All HW-2.1 SCD require wire insert details.

4.      Attachment detail for metal or plastic conduit conforming to SCD HW2.1.

5.      Non-corrosive lifting devices.

6.      Maximum opening is conduit outside diameter plus 1 inch (25 mm) for each conduit material type.

7.      All openings to be filled with nonshrink mortar including all lifting device voids.

8.      Changes in pre-approved drawings are the same as non pre-approved drawings.

9.      Detail how the 6 inch (150 mm) extension is treated if required.

10.    Fill the void between the precast half height headwall and the conduit by using nonshrink mortar.

11.    Apply marking, either stamped or painted, to the headwall to ensure each headwall size is matched to the proper conduit size and material type.

E.  Pre-cast structures for wing walls and headwalls for use with Items 706.05, 706.051,  706.052, and 706.053. The Contractor may provide precast wingwalls or headwalls in lieu of cast-in-place walls using the following criteria:

1.       Select fabricators that are prequalified and evaluated by the Office of Materials Management (OMM) according to Supplement 1073 and listed by the Department before the Contract Letting Date.

2.       All reinforcing steel shall be epoxy coated.

3.       Wall anchorage dowels shall be epoxy coated as per 709.00 or galvanized as per 709.16.

4.       Galvanize all connection hardware per 711.02.

5.       Install dowels per 510 using non-shrink, non-metallic 705.20 epoxy grout. 

6.       Provide the entrained air requirements as per the applicable concrete specification.

7.       Provide Non-corrosive lifting devices.

8.       Fill all openings including all lifting hook voids with non-shrink mortar per 705.22.

9.       Provide shop drawings detailing precast concrete structural elements and calculations according to the AASHTO LRFD Bridge Design Specifications.

10.    Have an Ohio Registered Engineer prepare, sign, seal and date the shop drawings. Have a second Ohio Registered Engineer check, sign, seal and date the shop drawings. The preparer and checker shall be two different Engineers. Have all questions and comments addressed before submitting the shop drawings.

11.    Submit the shop drawings and calculations to the Engineer at least 7 days before construction begins. Department acceptance is not required.  

12.    The Contractor’s written acceptance letter shall document acceptance of the shop drawings including confirmation of field verification, as required, and descriptions of issues resolved between the Contractor, the fabricator, or the Department.

13.    By accepting these shop drawings, the Contractor represents to the Department that all dimensions and elevations of existing conditions shown on the plans have been field measured and verified, and that these shop drawings comply with all the materials requirements, construction requirements, contract requirements, and performance criteria.  The Contractor further represents that these drawings have been coordinated and verified with the details of the work to be performed by other fabricators and entities on the project.  The Department will not make any allowance for additional cost or delays to the Contractor for incorrect fabrication as a result of failure to coordinate or perform this acceptance.

14.    If the Department requests changes on these shop drawings, or the Contractor makes changes in addition to those expressly requested, ensure that the shop drawings are accepted as above with suitable revision marks to identify the changes.

15.    Shop Drawing General Requirements:

a.Provide a separate shop drawing for each culvert location.

b.Provide on 11” x 17” sheets in pdf  (portable document format).

c. Show:

                                                                 i.      All dimensions.

                                                                ii.      Inlet and outlet.

                                                              iii.      North arrow.

                                                              iv.      Roadway centerline stationing.

                                                               v.      All construction phases.

                                                              vi.      Precast piece labels

                                                            vii.      Holes for conduits, framed with diagonal reinforcing on both faces.

                                                           viii.      Reinforcing Lap lengths

                                                              ix.      Material strengths

                                                               x.      Weep holes locations

                                                              xi.      Lifting device locations.

d. Label:

                                                                 i.      Project Number

                                                                ii.      PID

                                                              iii.      County Route Section of the structure

                                                              iv.      Stream Name as show on plans

                                                               v.      Structure File Number or Culvert File Number as given on the plans

                                                              vi.      Fabrication facility where units are to be cast


F.      Masonry units structures are headwalls, pipe cradles, collars, and other units. Thoroughly wet masonry units before laying the mortar. Lay masonry units with full mortar joints. Take adequate precautions to prevent the mortar from freezing.  Do not set masonry units having a temperature of 40 °F (4 °C) or less with mortar until heated.  When required, heat to ensure that a temperature of 50 to 80 °F (10 to 27 °C) is obtained throughout the entire masonry units. Cure the exposed surfaces of the masonry units by covering with wet burlap for 48 hours or by applying curing membrane according to Item 511. Construct the masonry units structures according to the corresponding Standard Construction Drawing. Use one of the following mortars:

1.      One part Portland cement to two parts sand by volume.  The Contractor may add lime in an amount not to exceed 10 percent of the cement by weight

2.      One part masonry cement to two parts sand by volume.

602.04  Method of Measurement.  The Department will measure Brick Masonry, Block Masonry, and Concrete Masonry by the number of cubic yards (cubic meters) calculated from dimensions shown on the plans.

602.05  Basis of Payment.  When a precast structure is used, payment is based on the number of cubic yards (cubic meters) required for the cast in place item and is considered full compensation for construction of the precast structure.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

602             Cubic Yard                      Brick Masonry
                       (Cubic Meter)

602             Cubic Yard                      Block Masonry
                       (Cubic Meter)

602             Cubic Yard                      Concrete Masonry
                       (Cubic Meter)