THIS REPORT CONSISTS OF THE FOLLOWING:

1. SECTION 1- BRIDGE FALLEN SPAN AND DAMAGED MEMBERS, ROAD AND WALKWAYS DESIGN

2. SECTION 2- CORROSION AND CORRECTIVE MEASURES FOR FALLUJAH BRIDGE

3. SECTION 3- ELECTRICAL SYSTEM, TRAFFIC AND OTHER AUXILLIARIES

 

  

SECTION 1

BRIDGE FALLEN SPAN AND DAMAGED MEMBERS, ROAD AND WALKWAYS DESIGN

 

  

Section 1

Analysis and design of Fallujah steel bridge:

1- Type of the bridge: The Fallujah Bridge has five spans Each span is simply supported span bridge and has two main straight longitudinal trusses of total length, c/c of steel rockers and steel rollers, clear height 5.64m or 6.065m c/c of upper and lower chord members. The distance between the two trusses is 4.88m i.e. the bridge was designed for single carriage way and two side walkways of width 1.6m on each side. See ST1, 2.

2- Geometry: No. of abutments 2 No. of piers 4 No. of spans 5 Total width of bridge 8.9m Side walkway width 1.6m Carriage way deck Side walkway slab thickness 170mm

3- Materials and strengths : 3.1- Concrete: Fcu = compression strength of standard cube 150×150×150mm concrete after 28 days = 33 Mpa ( SCRB requirements) SCRB = state commotion for roads and bridges. 3.2- Reinforcing steel bars to be used grade 60 ksi ASTM A616 grade 60 ksi, (413 MPa) Fu = 90 ksi (620Mpa) or equivalent steel reinforcing bars according to international codes. 3.3- Steel for truss members and beams for floor decks: 3.3.1 St 37-2 DIN 17100 or equivalent steel according to other International Codes Fu = 340-470 MPa for 3<t ≤100mm

 

  

Fy = 235 MPa for t ≤ 16 Fy = 225 Mpa for 16<t≤40mm Є = 24% Impact 27J for temp. +20ᵒ C 3.3.2- St 44-2,3 steel plates for truss members and beams and angles. DIN17100 Fu = 430 – 580 MPa Fy = 275 MPa for t ≤ 16mm Fy = 265 MPa for 16 <t ≤ 40 Єu = 20% Impact 27J for temp 0ᵒC 27J for temp -20ᵒC 3.3.3 43 D, or E BS 4360 British steel for hot rolled steel plates and steel sections Fu = 490-620 MPa Fy = 280 MPa for t≤16mm Fy = 270 MPa for 16<t≤40 Єu = 22% Impact 27J at -30ᵒC 41J at -20ᵒC 43D 27J at -50ᵒC 47J at -30ᵒC 61J at -20ᵒC 43E 3.3.4 St 52-3 DIN17100 for hot rolled steel plates: with specifications: Fu = 480-630 MPa for 3<t≤100mm Fy = 355 MPa for t≤16mm Fy = 345 MPa for 16<t≤40mm Єu = 22% for 3<t≤40mm Єu = 19% for 40<t≤63mm Impact 27J at +20ᵒC 3.3.5 Forged steel for steel rocker and roller: A668 class F ASTM with specifications Fu = 85 ksi Fy = 50 ksi Fb = 40 ksi

 

  

Fv = 20 ksi Fp = 40 ksi Fp rocker and roller = 20 ksi Єu = 20 % Brinell hardness = 174-217 3.3.6- The steel of the vertical web member VWM, steel of the inclined web member IWM and steel of lacing web was tested in the laboratory for testing steel plate .Test Results attached attachment 1 The results are tabulated below

Member Fu(MPa) Fy(MPa) Єu% Thickness t mm

VWM 433 310 28% 8-11

IWM 441 317 30% 10

Lacing 487 380 20% 9.5

4- Steel sections of truss members to be used : 4.1- UC Welded Upper Chord member St44-2,3 thickness of top flange

b/t=735/t =6140/ =30.23 t = 16.37mm use 18mm b=384 t= 12.7mm use 14mm See specification as below A= 282.12 cm² Ix = 72.659 E3 cm

Iy = 167.35 E3 cm⁴ rx = 16.049cm ry = 24.356cm Yc = 27.284cm Zx = 4.9374 E3 cm³ Zy = 2.6631 E3 cm³

 

  

4.2- BC Welded Lower Chord member St 44-2,3 See specification as below A = 210 cm² Ix = 52.15 E3 cm⁴

Iy = 163.16 E3 cm⁴ rx = 15.759 cm ry = 27.874 cm Zx = 2.474 E3 cm³ Zy = 4.47 E3 cm³ 4.3 Hot rolled steel section of St 44-2,3 Vertical Web Member VWM: Existing steel section [9”×3.2”×0.45×0.54”]( 228.6×88.9×11.43×13.716) A = 7.5 in² (48.3833cm²) , Ix = 89.3in⁴ , rx = 7.861 in (19.96 cm)

We Used as trial a section with double channel : CH229×89×32.7kg/m (228.6×88.9×8.6×13.3) A =41.48 cm² Ix = 3364 cm⁴ for single channel

rx = 9.01 cm ry = 2.57cm A = 2×41.48 = 82.96cm² rx= 9.01cm for double channel ry>rx result does not satisfy requirement Then we Tried welded section A = 4×9(1.5)+2(20)(1.2) = 102 cm² Ix = 2[9×1.5(10.75²×2+2.4/12(20³)= 7840cm⁴ rx = 8.767 Results suitable

 

  

4.4- As for Inclined Web Member IWM St 44-2,3 A = 2×31.5×1.5 = 93cm²

rx = = 8.948 cm

ry = = 21.25 cm

4.5 As for Welded section of External Web Member EWM St 44-2,3 A = 147 cm2 rx = 11.688 cm ry = 17.314 cm yc= 18.781 cm 4.6- Hot rolled steel section for Cross Beam St37-2 or St 44-2,3 UB533×210×122 (544.5×211.9×12.7×21.3) Ix = 76040 cm4 I20”×7 ½ “ ×0.6”×1.01” ×89 Sx = 2793 cm3 I508×190.5×15.24×25.654 Iy = 3388 cm4 Ix = 16727 in4 (696230 cm4) Sy = 319.7 cm3 Sx = 150.68 in3 (2469 cm3) 4.7- Hot rolled steel section for side walkways beam (St44-2,3) Channels CH152×89×24 (152.4×88.9×7.1×11.6) Ix = 1154 Sx = 151.4 Iy = 210 Sy = 34.5cm

5- Applied Loads : 5.1- Dead load D.L. R.C density 24 kN/m3 Steel density 76.985 kN/m3 Asphaltic surfacing density 22 kN/m3 5.2- Live loads L.L

 

  

Live loads are based on IRAQI standard specification for roads and bridges Revision 1978. 5.2.1 Civilian HA live load. a) Uniformly distributed load of WHA = 22.0618 kN/m/lane for L = 54m b) K.C.L 120 kN/ lane 5.2.2- Military loading :

a) Military tracked vehicle class 100 (90ton = 883kN) b) Military wheeled vehicle class 100 (1150 kN) No Military loading are allowed since road carriage way width 3.55m < 4.27-8.5m –allowed width for military vehicle use- as stipulated in Iraqi standard specifications for roads & bridges (loadings) revision 1978 5.2.3 Side walkway L.L: For L = 54m WL.L = 2.684 kN/m2 c/c of beams (channels) 1.6m for single span (AASHTO 1989) T = (S+10)/30 >= 0.542 S = 1.6m T = (1.6x3.28+10)/30 = 0.508’ Use T = (17cm)

 

  

d bottom = 170-50-8 = 112 mm for carriage way to avoid corrosion d top = 170 – 37.5 – 8 =124.5 mm for carriage way to avoid corrosion T min for side walkway 170mm d = 112mm WD = 0.17(24) = 4.05 kN/m2 WL.L = 3.64 kN/m2 Surfacing = 1.32 kN/m2 Total = 9.04 kN/m2 M D+L = 9.04 (1.6)²/8 = 2.08928 kN.m/m

d = = = 40.98 mm

As = 2.8928×10^6/(165×7/8×112) = 178.899 mm2/m As (min) = 0.18/100 × 1000×170 = 306 mm2/m Φ10 @ 79/306 ×1000 = 258 mm c/c Use Φ10@ 150 mm c/c (As) actual = 1000/150 ×79 = 527 mm2 >178.899 mm2

Top and bottom each way

6- Design of carriage way steel corrugated sheets St44-2,3: WD = 4.8+0.06(22)=6.12 kN/m2 c/c = 4.5m Live load (WL.L|100 = 3.42 ton/m/lane = 33.54 kN/m/lane WL.L /m2 = 33.54/3.05 = 11 kN/m2 120/3.05 = 39.34 kN/m WD+L = 6.12+11=17.12 kN/m2 MD+L = 17.12(4.5)^2/8 +39.34(45)/4 = 87.5925 kN.m/m Ix = 20(1)(2)(9.5)^2 + 2(1) 28.28³/12 ×0.707² = 3610+1884 = 5494.7 cm4 St,b = 5494.7/10 = 549.47cm3/0.8m = 686.8cm3/m

 

  

Fb = (87.5925×10^6)/(686.8×10^3) = 128 MPa o.k< 0.55(275) = 151.25 MPa For St44-2,3 For partial composite construction fb will be smaller As (min) = 0.18/100 × 1000×90 = 162 mm2/m Φ12 @ 113/162 ×1000 = 698 mm c/c Use Φ12@ 200 mm c/c (As) actual = 1000/200 ×113 = 565 mm2 >162 mm2

7- Design of side walkway channels: W= 9.04×0.8+(24/1000×9.807)+1.0= 8.4673 kN/m MD+L = 8.4673 (4.29²)/10 = 15.5833 kN.m Use CH152×89×24 Ix=1154 Sx = 151.4 Fb = (15.5833×10^6)/(151.4×10^3)= 102.928 MPa O.K <0.55(275) = 151.25 MPa for St44-2,3 V= 4.29/2 ×8.467×1.1 = 19.98 kN fv = (19.98×10^3)/(152.4×7.1) = 18.39 MPa O.K < 0.3(275) = 82.5 MPa for St44-2,3 WL.L = 3.64 (0.8) = 2.912 kN/m WL.L = 2.912 ×4.29= 12.49248 kN (2.8533 kip) ∆L.L = (1/185)×(2.8533/29000)×(4.29/2.54)³/(1154/2.45^4)=0.09242cm ∆L.L/L = 0.09242/429 = 1/464 O.K < 1/1000 for St37-2 or St44-2,3

8- Design of the cross beam UB533×210×122 WD = (4.8+0.06×22)4.5 +101/1000 ×9.807 = 28.53 kN/m WL.L for L = 9m WLL = 3.275 ton /m/lane WL.L/m2 = 3.275 ×9.807/305 = 0.53 kn/m2 MD = 59.913(2.22-1.025)=70.0982 (ML)HA = 73.6875 (2.22-0.7625)= 107.3995 (ML) = 87.45 kN.m ∑MD+ L = 264.947 Fb = (264.947×10^6)/(2793×10^3)= 94.86 MPa

 

  

O.K < 0.55(225)= 123.75 Mpa For St37-2 or 0.55(265)= 145.75MPa for St44-2,3 V= 193.6 kN Fv = (193.6×10^3)/(544.5×12.7)= 28 MPa O.K < 0.3(235) = 70.5 MPa for St37-2 WL.L = 60 +73.6375 = 133.6375 kN (30.53 Kip )

∆L.L 5/384 × ×5.54 = 0.10179 cm

∆L.L/L = 0.10179/440 = 1/4322 O.K< 1/1000 Cantilevered B.M due side walkway WD+L = 10(4.5)+0.99046 = 45.95046 kN/m MD+L = 45.99046 (1.78)^2/2 =72.858 kN.m

Fb = =26.1 MPa O.K <<123.75 MPa

Cantilever beam can be tapered safely Design of connection of cross beam to the vertical web member using 2L102×19 Load = 193.6+1.78×45.9905=276 kN Using M24(10.9)(Ft)AASHTO table 10.32-38 Ft = 25 ksi for St44-2

Rs.s = kN

R bearing = 24×8.6×1.1×275×10^13 = 60.436 kN No. of required bolts = 276/62.436 = 5 Use 16M24 grade (10.9)

 

  

9- Design of the truss members 10.1- Dead Load DL:

Member UC BC VWM IWM EWM

Wt/m kN/m

2.35 1.65 0.7 0.75 1.2

L m 4.5 4.5 (5.64)(6.5) 7.3 8.2

10.1.1- Wtruss = 1.155(55×2.35+45×1.65+11×6.5×0.7+10(7.3)(0.75)+2(8.2)(1.2)=379kN (39ton)

10.1.2 Top bracings:

 

  

W top bracings = 66 kN 10.1.3 Floor beams: Wsteel beams = 13(8.88)(0.7777)(1.1)+2×55×0.2×1.65 = 135 kN 10.1.4 Bridge deck Design: W Deck = 4×55(4.8+1.32)+2×55(4.08+0.66)= 1868 kN Lighting and hand rails Wlight = 3×55 = 165 kN ∑ wD.L = 379(2) + 135 + 1868 + 165 = 2992 kN 10.2 Forces in the main truss member 10.3 WD.L/m = 2992/2(54) = 27.72 kN/m/truss MD.L = 27.72(54)^2/8 = 10104 kN.m ML.L: WL.L = (22.0618 + 2×1.6×2.65)54=30.5418 kN/m (ML.L) truss = 30.5418/2 (54^2/8)+120(54)/8)= 6376.24 kN.m

 

  

MD+L Mae exact ML.L/ truss WL.L/truss = 22.0618/4.88 (4.88-(3.05/2 +0.48))+1.6×2.65 = 12.99747+4.24 = 17.2375 kN/m compared with 15.271 kN/m 120(17.2375)/ 22.0618 = 93.759 kN ML.L/ truss = 17.2375 (54^2/8)+93.759 × 54/4 = 6283.068 + 1265.74 = 7548.8 kN.m MD.L+L.L = 10104+7548.8 = 17652.8 kN.m O.K> 16480 kN.m (approx.) (R) L1 = (17.2375+27.72)27+93.759=1307.6 kN 1213.9+94= 1308 kN Truss concentrated load /node = 44.9575 (4.5) = 202.3kN Use 204 kN Using the computer (using MIDAS gen software) the force of each member are tabulated below

 

  

 

  

 

  

Design of U5 – U6 members See previous page Compression force = 2754+209.04=2963 kN Type of structural steel for bridge St37-2 Fy = 235 MPa for t ,=16 Fy = 225 MPa for 16<t<=40 St 44-2,3 Fu = 430-580 MPa Fy = 275 for t <=16 Fy = 265 for 16<t<= 40 St52-3 Fy = 355 MPa for t<=16 Fy = 345 MPa for 16<t<=40 According to AASHTO 1989 For Fy = 36 ksi (248 MPa) Fa = 16980-0.53 (kl/r) ² Fy = 50 ksi Fa = 23580-1.03 (kl/r) ² Steel section U5-U6 Top chord A = 282.12 cm2 rx = 16.049 ry = 24.284 fa = (2963×10^3)/(282.12×10^2)= 105 MPa kl/r = 450/16.049 = 28 For St 37-2 Fa = 34/36 [16980-0.53(28)²=15644 psi (107.8Mpa) (fa/Fa)St37-2 = 105/107.8 = 0.974 O.K <1 For St44-2,3 Fa = 270/248[16980-0.53(28)²=18033 psi (124Mpa) (fa/Fa)St 44-2,3 = 105/124 = 0.8467 O.K <1 For St52-3 Fa = 23580-1.03(28)²= 22772 psi (157Mpa) (fa/Fa)St52-3 = 105/157 = 0.669 O.K <1

 

  

Bolted connection using M24 (10.9)

Rs.s = = 0.7012 (25) = 17.53 (76.749kN)

(Rbearing) = 24×14×1.1×275×10^3 = 101.64 kN St 37-2, t= 15mm No. of bolts = 2963/76.14 = 39 bolts total 78 bolts For St 44-2,3 and St 52 -3 same No. of bolts is used Bolted Top chord splice detail: Use [ 5+ 4×2+2×1] ×3×2 = 90 bolts O.K > 39 bolts

Use double lacing 2L65 ×7 St 44-2,3 = 73.3 St37-2 A= 8.7cm2 rz = 1.26 Kl/r = 73.3/1.26 = 58 Fa= 275/248(16280-0.53(58)^2)= 16015 psi (110MPa)

P= 8.7 (10^2)(110)×10^-3)=96 kN O.k> 0.1 (1965) = 29.66 = 42 kN

Or use IP 65××20 10 curgrx = = 0.377 cm kl/r=73.3×0.9/0.577=114

Fa = 275/248 [ 16280-0.53 (114)] = 10414 psi = 71.82 MPa

fa = (29.66×( )(10^3))/(65×20)= 32.25 MPa

 

  

fa/Fa = 32.25/71.82=0.44 Design of L6- L7 Bottom chord A= 210cm2 rx = 52.15 cm Zx = 2.4833 E3 cm#

TL6-L7 = (2751.7×10^3)/210102=131 MPa

(Ft)St37-2 = 0.55× 225=123.75 MPa (ft/Ft) St37-2 = 131/123.75 = 1.0585 not O.K > 1 (Ft)St44-2,3 = 0.55×265=145.75 MPa (ft/Ft) St44-2,3 = 131/145.75 = 0.8987 O.K (Ft) St52-3 = 0.55×345 = 189.75 (ft/Ft)St52-3 = 131/189.75 = 0.69 O.K<1 Moment due to side walkway slab 0.8(4.75)(4.29)²/10 = 8.9788 kN.m Fb= 8.9788(10^6)/(2.4833(10^6)/2) = 7.2313 Mpa (ft/Ft + fb/Fb) St44-2,3 = 0.8987 +7.2313/145.75 = 0.948 O.K < 1 (ft/Ft+ fb/Fb) St52-3 = 0.696 + 7.2313/189.75 = 0.728 O.K<1 Bolted bottom chord splice details Rs.s = 76.74 kN (Rbearings) t = 152 St44-2,3 = 24×15×1.1×275×10^-3 = 108.9 kN No. of bolts = 2533.2/76.47 = 34 bolts Total 68 bolts use 96 M24 (10.9)

 

  

Use single lacing 2L60×6×5.42 L= 73.3 St37-2 Design of Vertical web members U1 L2, U2 L3, U3 L4, U4 L5, U5L6, U6L7 Forces in the vertical members

U1L2 U2L3 U3L4 U4L5 U5L6

204 714 510 306 102

94 62 62.66 34 47

T = 298 kN C = 776 kN C = 572.6 kN

C = 360 kN C = 149 kN

A = 102 cm2 rx = 8.769 cm ry>rx fa = 776(10^3)/102(10^2) = 76.13 MPa kl/r = 607/8.763 = 69.3 (Fa) Fy = 248 = 1680-0.53(69.3)^2= 1.5715 psi (108MPa) (Fa) St 44-2) = 102.9 (270/248) = 116 MPa

 

  

(fa/Fa) St 44-2 = 69.3/108 = 0.641 O.K <1 Design of end connection For M24 (10.9) Rs.s = 76.74 kN (Rbearing) = 24×12×1.1×280×10^-3 = 88.77 kN T= 10 St52-3 No. of bolts U2L3 = 776/76.14 = 11 bolts Use 16 M24(10.9) For U3L2 572.6/76.14 = 8 bolts Use 12 M24(10.9) For U4L5 360/76.14 = 5 bolts Use 8 M24(10.9) For U5L6 149/76.14 = 2 bolts Use 8M24(10.9) For U1L2 298/76.14 = 4 bolts Use 8 M24(10.9) Design of Inclined web members U1L2, U2L3,U3L4, U4L5, U5L6 (IWM) Forces in the Inclined web Member IWM

U1L2 U2L3 U3L4 U4L5 U5L6

1148 893 638 381 127

97.5 87.759 75 58.5 58.5

T = 1246 981 716 440 168 kN

A= 93 cm2 rx = 8.948 cm ry = 21.25 cm U1L1: ft = 1246(10^3)/93(10^2)= 133.98 MPa (Ft) St 44-2,3 = 0.55×275 = 15125 MPa (ft/Ft) St44-2,3 = 133.98/151.25 = 0.88 O.K <1 For member U2L3,U3L4, U4L5 use the same steel section For U5L6 use section item 4.3 for St 44-2,3 Rs.s 76.14 kN Rbearing = 24×15×1.1×275×10^-1 = 108.9 kN End connection For St 44-2

 

  

U1L2 No. of bolts = 1246/76.14 = 17 bolts use 24M24(10.9) U2L3 No. of bolts = 981.7/16.14 = 13 bolts use 18 M24(10.9) U3L4 No. of bolts = 710/76.14 = 10 bolts use 18 M24(10.9) U4L5 , U5L6 No. of bolts = 440/76.14 = 8 use 12M24(10.9) Design of External Inclined Web member L1U1 Force = 1402.5+107.26 = 1510 kN See item 4.5 A= 147cm2 rx = 11.688cm ry = 7.314cm yc = 18.781 cm kl/r = 1.021×100/11.688 = 60 fa = 1510(10^3)/147(10^2) = 102.72 Mpa [(Fa)fy=36 ksi(248Mpa)]St44-2,3 = 275/248[16980-0.53(60^2)]1/145=115 MPa (fa/Fa)St 44 -2,3= 102.72/115 = 0.893 O.K <1

b/t = 6140/ = 30.748 O.K > (440-24)/15 = 27.73 say O.K Design of End connections : Rs.s = 76.74 kN (R bearing) t=12 St44-2,3 = 24×12×1.1×275×10^-3 = 187.12 kN No. of bolts =1503.96/76.74 = 20 use 24M12(10.9) U1U2 C = 1512+116.13=162.13=1628.3 kN No. of bolts = 1628.3/76.74 = 22 bolts Use 30 bolts M24(10.9) See rocker and roller Fig. Top cylinder ϕ 125×915m Reaction = 1224+94 = 1318 kN

 

  

Forged steel for rockers and rollers A66 class F according to ASTM Fu = 85 ksi Fy = 50 ksi Fb = 40 ksi Fv = 20 ksi Fb = 40 ksi (Fb) rocker and rollers = 20 ksi Єu = 20% Brinell hardness = 174-217 fp = (1318×2.24×1000)/(150×735×9.807/25.4²) = 1762 psi O.K 20000 psi 5ϕ125 ×735 rollers 1p= (Fy-13000)/20000 *600 d = (50000-13000)/20000 * (600×5.9055) = 6555 lb/in = 6.555 kip/ in Reaction = 5(73.5/2.54)(6.555)9.807/2.24 = 4152 kN O.K > 1318 kN See steel rocker and steel rollers bottom plate Bottom plate of rocker = 920×1225mm Bottom plate of roller = 780×1035mm fp = 1318000/(920×1225) = 1.16947 MPa fc’ = 33×0.8=26.4 MPa (SCRB) fp/fc’=1.16947/26.4=0.0443 O.K <0.25 or 0.35 AISC 1989 fp = 1318000/(780*1035) =1.6326 MPa fp/fc’ = 1.6326/26.4 = 0.06184 O.K < 0.35 AISC 1989 Bearing between steel rollers or rockers See rocker and roller drawing Top plate size = 610×735mm (fb)steel = 13181000/(610*735) = 2.93966 St44-2,3Fy = Mpa for t= 55mm (fb) steel/fy = 2.93966/265=0.01109 O.K <0.9

 

  

Truss deflection Area of upper chord A = 282.12cm2 Area of lower chord A = 210 cm2 282.12 y = 210 (6.07-y) 492.12y = 6.07×210 y = 2.59022m 6.07-y = 3.47977m Moment Of Inertia @ Neutral Axis (IN.A) =282.12×(259.022²)+210(347.977²) = 18,928,106.9+25,428,478 =44,356,585 cm4 Deflection ∆ for D.L: WD = 1500 kN (342.62 kip) ∆D = 5/384 × (342.62(5400/2.54)³)/(29000*4.4356585/2.54⁴) = 1.3. ”

7108 (3.52325cm) Deflection due to flexure + shear deflection (∆D)total = 4/3 * 3.52325 = 4.697556 cm (WL.L)HA = 931 kN (∆L.L)HA = 4.69755*931/1500 = 2.9156cm ∆L.L=∆HA+ ∆ KEL

 

  

R KEL = 94 kN (21.47 kip) (∆L.L)KEL = 21.47/48 *(5400/2.54)³/(29000*44356585/2.54⁴=0.139075”(0.35325cm)

∆L.L = 2.9156+0.35325 = 3.26885cm ∆L/L = 3.25885/5400=1/17651 O.K <1/1000) ∆camber = 100 sin The deflection of the Truss is shown in Midas Gen attachment 2 below

 

  

11- Design of steel expansion joint: For L = 9m WHA = 32.12 kN/m/lane KEL = 120 kN WD = 4.8+ 0.06(22)4.5+2.31 = 11.85 kN/m MD+L = [11.85+32.12×4.5]3.035/8 +120×3.035/4 = 59.33+91.05=150.38 kN.m Ix = 2(30)(2)(14.5)²+3(27³)/12 = 30150 cm⁴

Sx = 30150 cm ⁴/15.5 = 1945.2 cm3

Fb = 150.38(10^6)/1945(10^3) = 77.316 MPa O.K < 0.55 (265)= 145.75 MPa V = ½ [11.85×3.035+32.12(4.5)+120] = 100.25kN Fv = 100.25(10^3)/(30×270) = 12.37 MPa O.K < 0.3(275) = 82.5 WL.L = 32.12 (4.5)+120=264.54 kN (60.42 kip) ∆L.L = 5/384 * (60.42(303.5/2.54)³)/(29000*30150/2.54⁴) = 0.06389”

(1.6228mm) ∆L.L/L = 1.6228/3035 = 1/1870 O.K < 1/1000

 

  

12- Side walkway expansion joint Design 3.605/2 + 0.895= 2.695 m WD = 0.17(24)= 4.08 kN/m = 5(1.515)(2.695)= 20.414 kN MD = 20.414(1)=20.414 kN.m (fb)D = 20.414(10^6)/560.5(10)^3 = 36.46 MPa Fb = (20000-7.5(2×1515/165)²)275/248 =19372 psi (133 MPa) (fb/Fb)D = 36.46/133 = 0.274 O.K <1 WD+L = 2.695 (1.6)(9.04)=39.058 kN M = 39.058(1) = 39.058 kN.m S = 39.058(10^6)/0.55(275)(10^3) = 265.9 cm3 UB 305×165×46 (303.4×165×10.2) Ix = 8503 cm4 Sx = 560.5 cm3 (fb) D+L = 39.05(10^6)/560.5(10^3) = 69.669 MPa O.K < 0.55(275) = 151.125 MPa (fb/Fb)D+L = 69.669/151.125 = 0.46 O.K < 1 Use M20(10.9) Fr = 48.5 ksi F = 39.05/0.615 = 63.4959 kN Use M20×(10.9)Rt = 0.4869×48.5 = 23.616 (231kN) Use 2 M20 ×(10.9)= 231 ×2=462 kN> 63.4959

 

  

 

  

ATTACHMENT-1

Material Testing Results of Different samples from Falluja Bridge

Lab report

 

  

 

  

 

  

 

  

 

  

ATTACHMENT- 2

MIDAS software Report results

 

  

 

  

 

  

 

  

 

  

 

  

 

  

 

  

 

  

 

  

 

  

 

  

SECTION 2

CORROSION AND CORRECTIVE MEASSURES FOR FALLUJAH BRIDGE

 

  

Contents

1 General 2 Bridge cleaning

o 2.1 Removal of accumulated Foreign Materials o 2.2 Loosely Adherent Paint o 2.3 Water washing                       

3 Blast Cleaning and Surface Preparation o 3.1 Abrasive Blast Cleaning o 3.2 Standards for Surface Preparation of Steel Structure

Abrasive Blasting Removal of Existing deteriorated Paint by Mechanical Method

4. Painting of Structural Steel

o 4.1 General o 4.2 Material Acceptance o 4.3 Paint System

4.3.1 Primer Coat 4.3.2 Intermediate Coat 4.3.3 Finish Coat

o 4.4 Applications 4.4.1 Penetrating Sealer 4.4.2 Prime Coat 4.4.3 Intermediate coat 4.4.4 Finish Coat

o 4.4.3 Re-coating 4.4.3.1 Surface condition 4.4.3.2 Minimum time 4.4.3.3 Maximum Time 4.4.3.4 Mixing

5. BoQ’s

 

 

 

 

 

 

  

1. General 

Structural steel: Structural steel elements in new structures are usually either hot

rolled sections or fabricated plate girders. The initial steel surfaces normally comply with rust grades A or B according to BS EN ISO 8501-1. Material that is pitted, i.e. rust grades C or D, are not relevant to the present conditions of the corrosion of the bridge. Descriptions of rust grades A to D are as follows (Figure 1):  

A - Steel surface largely covered with adhering mill scale, but little if any rust B - Steel surface which has begun to rust and from which mill scale has begun to flake C - Steel surface on which the mill scale has rusted away or from which it can be scraped, but with slight pitting under normal vision.

D - Steel surface on which the mill scale has rusted away and on which general pitting is visible under normal vision.

In Falluja bridge work, only categories A and B are assessed to have affected the bridge hence recommended for the repair of the bridge.

                             

   Figure (1) Representative photographic examples of corrosion grades in steel 

Bridge status: Figure 2.a. shows a schematic diagram of the existing Falluja 

bridge, of length 274.3 m. It consists of five spans each of average length 54.6 m, 

span 4 was destroyed completely. For decades, no proper metallurgical based 

service and maintenance have been made on the bridge and was exposed to 

 

  

sabotage. Large part of the bridge structure was exposed to corrosion. Aging 

paint and corroded facia of the structure, must be removed and repainting applies to

the bridge spans 1,2,3, and 5, whereas work on span 4 (newly designed) includes painting only .Figure (2.b) shows an examples of corrosion grades in parts of Falluja steel structure. 

 

  

Following is a list of equipment and tools to be used in this work for the removal of existing aging paint, accumulated foreign materials and for painting the bridge structure:

1. Abrasive blast cleaning equipment 2. Conventional Air Compressor(s) used in abrasive blast cleaning, blowing down

surfaces, and in painting with conventional spray must be in accordance with the requirements of ASTM D-4285.

3. Vacuum cleaner for general purposes. 4. High pressure water jetting system (around 100 bar). 5. Hand brooms, hand shovels, scrapers, hand wire brush, rotary wire brush and

rotary grinder. 6. Personal Protective Equipment:(Protective equipment, including personal

protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition). Standards- 29 CFR, number 1910.1132, OSHA -USA .

7. Containers, include ground storage bins, water tanks, steel structures used for storage and storage for paints and painting equipment (hand and power machine) .

8. Coating Thickness Gauge (CTG): This compact gauge can be used for non-destructive coating thickness measurement of non-magnetic coatings, e.g. paint, chrome on steel. ASTM D7091-13, Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals. Or, ISO 19840 Paints and varnishes--corrosion protection of steel structures by protective paint systems--Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces

2. Bridge cleaning 

Cleaning work involves removing accumulated foreign material, loose paint, corrosion and water washing the existing spans 1,2,3, and 5. The cleaning process involves an estimated effective surface area equal to 10000 m2.  

2.1 Removal of Accumulated Foreign Material. Prior to water washing, all accumulated foreign material shall be removed from beams, member flanges, gusset plates, abutment bridge seats, pier tops, truss joints, deck drains, and at other locations under the supervision of designated engineer. The accumulated foreign material shall be removed by hand brooms, hand shovels, vacuum cleaners or other methods acceptable to the engineer. The removed material shall be collected and disposed at an approved waste

 

  

area in accordance with the local regulations and in areas as authorized by local authority. At any circumstances, shall NOT this removed material be allowed to fall or contaminate in the river water or on the land below the bridge. We recommend in addition to the curtains required for the Falluja bridge works, impermeable tarpaulin must be used under the bridge to catch and contain the falling debris.

2.2 Loosely Adherent Paint. Loosely adherent paint shall be removed in areas designated for painting using hand tool methods in accordance with the SSPC-SP2 standard (Appendix A), prior to water washing. All paint removal operations will require containment as specified earlier in this report.

2.3. Water Washing. Prior to abrasive blast cleaning, steel surfaces to be repainted, abutment seats, pier caps, and other surfaces of the bridge structure shall be washed with high-pressure water (100 bar) to remove salt contaminants, dirt, and other detrimental foreign material. Detergents or cleaners and scrubbing may be needed in conjunction with water washing. The water shall be clear fresh water that is free of sediments and salt contaminants. After water cleaning, all oily or greasy residues shall be cleaned with solvent in accordance with SSPC-SP1.

3. Blast Cleaning and Surface Preparation.

The actual surface preparation and cleaning procedure must be done in accordance with (SSPC)- Surface Procedure(SP) Specifications. The specifications define the condition and texture of surfaces after cleaning.

3.1 Abrasive Blast Cleaning. This work involves preparing all designated surfaces to be painted by abrasive blasting using conventional equipment.

Some hand-tool and/or power-tool cleaning may be required in areas not fully accessible to the other methods.

Abrasive blasting systems shall incorporate abrasive recycling to reduce waste volume to the greatest extent possible.

The standard grades of cleanliness for abrasive blast cleaning in accordance with BS EN ISO 8501-1 are:

Sa 1 – Light blast cleaning Sa 2 – Thorough blast cleaning

 

  

Sa 2½ – Very thorough blast cleaning Sa 3 – Blast cleaning to visually clean steel

Specifications for Falluja bridge steelwork requires grade Sa 3. Appendix B shows a representative example of surface preparation grades of steel.

3.2 Standards for Surface Preparation (Appendix C)

The following standards provide photographs of what surfaces should look like after cleaning step, i.e., surfaces are ready for painting, so that one will have a guide to judge the quality of the actual work

SSPC-VIS 1: Guide and Reference Photographs for Steel Structures Prepared by Dry Abrasive Blast Cleaning.

SSPC-VIS 3: Guide and Reference Photographs for Steel Structures Prepared by Hand and Power Tool Cleaning

These guides contain a series of full-color photographs to be used as

supplement to the SSPC standards and can be purchased. Samples of

SSPC standards with selected photographs are illustrated in Appendix B. Supervising engineer who confirms that the surfaces are ready for painting, should have good experience in comparising between the guide photos and the actual surface, i.e., a trained eye engineer. 3.2.1 Abrasive Blasting. Areas to be painted shall be prepared by a dry abrasive blast method to a level (SSPC-SP6 and/or SSPC-SP10), Figure 3. The current SSPC-VIS1, Visual Standard for Abrasive Blast Cleaned Steel, will be used in conjunction with the appropriate written SSPC Standard for acceptance of final surface preparation. Surface profile (etched height) shall be 25 µm to 50 µm as measured by replica tape or surface profile comparator.

 

  

Small areas that cannot be cleaned using abrasive blasting equipment shall be prepared using hand-tool and/or power-tool methods. SSPC Standards applicable to the method(s) applied will be used to evaluate surface preparation.

After blasting or mechanical preparation, the surface to be painted shall be thoroughly cleaned with dry, oil free, compressed air, and/or HEPA Vacuums to remove all adhering blast residue. All oily or greasy residues shall be removed with solvent in accordance with SSPC-SP1. Solvent cleaning, for example, domestic kerosene may be used).

3.2.2 Removal of Existing Deteriorated Paint by Mechanical Methods.

Some repaired parts of the steel structure of the bridge may not be easily reached by using the blasting method, therefore the designated areas to be painted shall be cleaned by mechanical method and this will be: Areas of deteriorated paint where the existing top coat is peeled or deteriorated and the underlying existing primer is in sound condition. In such cases the work involves removing only the existing top coat by manual methods in accordance with SSPC-SP2 so the underlying existing primer is left in place. The deteriorated top coat shall be removed back to the boundary of adhering top-coat. A soundly adhering top-coat is defined as that which cannot be lifted from the primer with a putty knife.

Mechanical methods of surface preparation shall be in accordance with SSPC-SP2 and/or SSPC-SP3 as modified below.

Replace Article 3.5 of SP2, Hand Tool Cleaning, with the following:

3.5 SSPC-VIS3, Visual Standards for Power and Hand-Tool Cleaned Steel, shall be used to evaluate the degree of cleaning.

Replace Articles 2.2, 2.3, and 5.3 of SSPC-SP3, Power Tool Cleaning, with the following:

2.2 It is intended that power tool cleaning remove rust, deteriorated paint, detrimental foreign material, and loose mill scale that can be removed by vigorous use of the power tools.

2.3 SSPC-VIS3, Visual Standard for Power and Hand-Tool Cleaned Steel, shall be used to evaluate the degree of cleaning.

5.3 Use power wire brushing, power abrading, power impact, or other power rotary tools to remove rust, deteriorated paint, and loose mill scale. Do not burnish the surface.

After mechanical preparation, the surface to be painted shall be thoroughly cleaned with dry, oil free, compressed air, and/or HEPA Vacuums to remove all

 

  

adhering blast residue. All oily or greasy residues shall be removed with solvent in accordance with SSPC-SP1, Solvent Cleaning

Remark (1): A rust bloom or flash rust may be developed as visible rust on bare metal surface after cleaning. If bloom rust or flash rust occurs after removal of existing paint, or if a surface is cleaned and left unpainted for more than 24 hours, the surface shall be re-blasted or brush blasted just prior to the application of the first coat of paint.

Remark (2): In the blasting process, it is recommended to use steel shot and/or grit, aluminum oxide, or garnet abrasives. This is to ensure hard durable abrasives are used, to encourage abrasive cycling, and to minimize waste generated by this work. Abrasives must be clean, dry, and free from contamination. Sand is not recommended as abrasive in this work.

4. Painting of Structural Steel

4.1 General

Painting involves all five spans of the bridge. The effective surface area is assumed to be equal to 15000 m2 . This work consists of fully repainting, zone painting, and/or spot painting structural steel at designated locations. The work includes furnishing the coating system specified, application, protection, and curing of paint coatings; protection of all parts of the structure from paint spatter; environmental protection; final cleanup; and supplying all equipment, scaffolding and rigging, labor, and materials.

4.2 Material Acceptance.

1. All paints shall be equal to or less than 5.5 kg/L for volatile organic compounds (VOC). Calculation of VOC content shall account for any thinning necessary for field application.

2. A certification document for each shipment intended for use on this work is required from the coating manufacturer. The document shall include the following information:

a. date of shipment to the work site,

b. name of painting Contractor or company to which the shipment was made,

c. brand names and product identification numbers,

 

  

d. coatings, thinners, and tints supplied shall be accompanied with the most current Technical Data sheets and Material Safety Data sheets (MSD),

e. batch or lot numbers and producer mill certificate for any zinc pigment, certifying compliance to at least the purity requirements of ASTM D 520 Type II.

4.3 Three-Coat Painting System The paint system includes: Epoxy, Moisture Cured Urethane, or Zinc Silicate, for this work. Three different systems are applied in this work, as follows:

4.3.1 Primer Coat. The primer is applied directly onto the cleaned steel surface. The prime coat shall be a Zinc-rich Epoxy, or Zinc-rich Aromatic Moisture Cured Urethane, or Zinc-rich Silicate applied at a rate that results in a targeted dry film thickness (DFT) of:

a. 75 to 125 µm for Epoxy.

b. 75 to 100 µm for Moisture Cured Urethane.

c. 75 to 125 µm for Zinc Silicate.

There is no color specified for the primer.

Dry film thickness listed assumes a surface profile of 25 µm to 65 µm.

4.3.2. Intermediate Coat. Intermediate coats are applied to ‘build’ the total film thickness of the system. Generally, the thicker the coating the longer the life. Intermediate coats are specially designed to enhance the overall protection and, when highly pigmented, decrease permeability to oxygen and water. An intermediate coat shall consist of an Aluminum Epoxy Mastic or Aromatic Moisture Cured Urethane applied at a rate that results in a targeted DFT of:

a. 125 to 175 µm for Aluminum Epoxy Mastic (AEM).

b. 75 to 100 µm for Moisture Cured Urethane, pigmented with micaceous iron oxide

. c. No intermediate coat is required for a zinc-rich silicate system. The intermediate coat shall be tinted to a different color than the primer and finish coats

For painting the bridge, AEM is more suitable for use because it showed good

 

  

resistance to fresh water, salt water and weathering, (Article 1008.03(e) of the Standard Specifications for Road and Bridge Construction (January 1, 2007), Bureau of Materials and Physical Research -USA)

4.3.3. Finish Coat. The finish coat provides the required appearance and surface resistance of the system. Depending on the conditions of exposure, it must also provide the first line of defense against weather and sunlight, open exposure, and condensation. The finish coat shall consist of an Aliphatic Polyurethane, or Aliphatic Moisture Cured Urethane, or Waterborne Acrylic applied at a rate that results in a targeted DFT of:

a. 75 to 125 µm of Aliphatic Polyurethane for the Epoxy system.

b. 50 to 75 µm of Aliphatic Moisture Cured Urethane.

c. 50 to 75 µm of Waterborne Acrylic for the Zinc Silicate system.

Total DFT for painting steel structure of Falluja bridge shall be between 275 and 425 µm. The top coat shall be according to the SCBR code number for one-way bridges, most likely green color. More options of choosing painting system are available, Figure 4. Coating thickness shall be measured in accordance with SSPC-PA2 and ASTM D7091-13 standard (see para. 4.4.3.5).

4.4 Paint Application.

 

  

4.4.1 General. Paint may be applied using brush, roller, or spray methods and shall be applied in strict accordance with the coating manufacturer's latest written recommendations. Regardless of the method of application, the specified minimum DFT shall be achieved and the manufacturer's recommended maximum DFT requirement for each coat shall not be exceeded. Further:

a. All product parameters such as application, thinning, mixing, pot life, ventilation, curing, etc. shall be in accordance with the manufacturer's recommendations.

b. The prime, intermediate, and finish coats shall have a smooth, uniform appearance free from runs, sags, cracks, dry spray, over-spray, or other defects.

c. Concrete and galvanized products shall be adequately shielded so that application of paint on steel is full and complete without over-spray.

d. The supervising engineer shall be afforded OSHA compliant access to check the surface preparation before painting and the DFT after each coat is applied.

4.4.2 Painting

Before any painting begins, the contractor must provide a method for protecting water bodies, vehicles and any other property within the vicinity of the painting operation from being sprayed by paint. The contractor must provide screens, enclosures to contain overspray. In case of using non-spray applications methods like brushes or rollers, drips and excess paint can still fall in the river or objects below; therefore, protection must still be provided. Procedures and laws related to worker safety apply to the application of paint just as they do to the removal of paint

4.4.2.1. Penetrating Sealer. Penetrating sealer shall be applied to areas designated by the engineer. Penetrating sealer shall be allowed to cure according to the coating manufacturer's recommendations before the prime coat is applied.

4.4.2.2. Prime coat. All blasted and/or mechanically cleaned areas shall receive a prime coat. This coat shall be applied to areas of bare metal within 24 hours of being blast cleaned. If the prepared surface shows any sign of flash rust, or if the prime coat is not applied within 24 hours after blast cleaning, the entire prepared area shall be brush blasted before paint is applied. Areas prepared by mechanical

 

  

methods, which show flash rust, shall be re-prepared by methods acceptable to the Engineer.

Special attention shall be paid to all rivets, bolts, edges of connections, areas of pack rust, and areas which may be difficult to access. These areas may require ringing/stripping.

The prime coat shall be allowed to cure according to the coating manufacturer's recommendations before the intermediate coat is applied.

4.4.2.3. Intermediate coat. The intermediate coat shall be applied to all areas that received a prime coat and shall be allowed to cure according to the coating manufacturer's recommendations before the finish coat is applied.

The Zinc Silicate system does not require an intermediate coat.

4.4.2.4. Finish Coat. The finish coat shall fully cover the intermediate coat. The finish coat shall also fully cover other surfaces if so designated in the contract documents.

4.3.3. Recoating.

4.4.3.1. Surface Condition. Prior to painting, all surfaces shall be free of all dirt, oxidation products, oil, and other detrimental material. Any cleaning which may be necessary shall be done in a manner that is recommended by the coating manufacturer. All painted surfaces shall be protected to prevent soiling or detrimental weather conditions during painting and through the tack-free stage.

4.4.3.2. Minimum Time. No additional coat(s) of paint may be applied until the preceding coat has dried. Recoating shall be in accordance with the coating manufacturer's recommendations for time, temperature (ambient and/or surface), and weather conditions. If minimum recoat times are not given by the coating manufacturer, the previous coating shall have been applied for at least 24 hours, and be tack-free, prior to application of another coat.

4.4.3.3. Maximum Time. The coating manufacturer's maximum time between coats shall not be exceeded. If the maximum recoat time is exceeded for any coat, the coating manufacturer's technical representative shall provide a written correction procedure, or approval to proceed without correction, to the Engineer.

 

  

4.4.3.4. Mixing. Mixing of paint shall be in accordance the coating manufacturer's recommendations. Previously opened, or partially used containers of paint shall not be used and partial kit mixing will not be allowed.

The Contractor and coating manufacturer shall provide a specific mixing procedure for review by the Engineer prior to performing the work. This procedure shall be followed, unless a written request to modify is approved by the Engineer.

4.4.3.5. Dry Film Thickness. The Engineer will determine the DFT of each coat and the total paint system using procedures described in SSPC-PA 2 and ASTM D7091-13 standard. Excessive coating thickness is as equally undesirable as unacceptably thin coating thickness, and both will be sufficient cause for rejection. .

4.4.3.6. Application Conditions. The manufacturer's published weather restrictions for each coating are required. When painting, weather conditions shall be such that the surfaces to be painted are entirely free from dust, moisture, frost. When painting in an area protected from the above conditions, the surface shall remain under cover until the paint is dry. Wet paint exposed to humidity, rain shall be permitted to dry; and damaged paint shall be removed, the surface recleaned, and repainted.

In addition, Moisture Cured Urethane coating may only be applied when the:

a. surface temperatures are between 4°C and rising and 37°C.

b. relative humidity is less than or equal to 95%.

Bubbling or pin-holing which may occur in Moisture Cured Urethane will be evaluated using SSPC-VIS2. Bubbling or pin-holing shall be less than 0.1% as defined by SSPC-VIS2, Photographic Standard No. 8.

5. Bill of Quantity: Following is a summary of BOQ’s for rehabilitation of Falluja Bridge – works titled: Falluja Bridge: Corrosion and corrective measures

Preparation and Issuance of Detailed Design Proposal including BoQ’s, technical specifications, budget estimates, drawings, material specifications, and any other documents

 

  

 

Appendix A

Surface Preparation Standards

The basic standard for preparing metal substrate are a joint effort between the Society for Protecting Coatings (SSPC) and the National Association of Corrosion Engineers International (NACE)

SSPC-SP 2 Hand Tool Cleaning: Remove all loose mil scale, loos rust, loos paint, and other loos detrimental foreign matter made by power wire brushing, scraping, sanding, and wire brushing.

SSPC-SP3 Power Tool Cleaning: Remove all loos mill scale, loos rust, loos paint, and other detrimental foreign matter by hand chipping, scraping, sanding, and wire brushing.

SSPC-SP6 / NACE 3 Commercial Blast Cleaning: When viewed without magnification, the surface shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products, and other foreign matter of at least 66-2/3 % of unit area, which shall be a square 3 in x 3 in (9 sq.in) [7.6 x 7.6 cm (58 sq. cm)]. Light shadows, slight streaks, or minor discolorations caused by strains of previously applied coatings in less than 33-1/3 % of the unit area is acceptable.

SSPC-SP10 / NACE 2 Near-white Blast Cleaning: When viewed without magnification shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter of at least 95% of each unit area. Staining shall be limited to no more than 5% of each unit area, and may consist of light shadows, slight streaks, or minor discolorations caused by strains of rust, stains of mill scale, or stains of previously applied coatings. Unit area shall be approximately 3 in x 3 in (9 sq.in) [7.6 x 7.6 cm (58 sq. cm)].

 

  

Appendix B. Photographic examples of surface preparation grades of steel

ISO 8501- Corrosion Protection of Steel by painting.

 

  

 

 

 

 

 

  

END OF SECTION 2

SECTION 3

ELECTRICAL SYSTEMS, TRAFFIC AND OTHER AUXILLIARIES

 

  

Fallujah Bridge Electrical Systems

1. Introduction

The main aim of this section to describe and provide technical requirement and BOQ for Electrical Systems, it also specifies the bridge lighting devices and its connection, also our suggested standard traffic signaling and colors to regulate movement & prevent possible vehicles congestions/collisions.

2. Electrical systems

The bridge in its current state possess 3 phase electrical network /distribution bare cabling, to provide electrical transmission / distribution between two sides of the city ,the connection composed from mini tower with classic bushings fixed on top part of bridge carrying the 3 phase bare conductors see Fig 1 below.

Fig 1

It was noticed during detailed inspection of the bridge, that the current connections were not interrupted or disconnected due to the bridge one segment fall into the river see Fig 2 below, the electrical connection remains in its natural shape to provide required electrical energy transfer and distrbution. Accordingly we recommend keeping the electrical connection as it is now with adding the similar support and insulation segment in the fallen span of the bridge to the newly designed span.

Fig 2

3. Bridge Lighting

In order to have clear vision at night, we recommend the use of outdoor LED street

lighting unit.

This type has efficient, improved light reflect rate and light efficiency.

We recommend the QTY of two complete units to be distributed along each bridge

segment, one at the start of the bridge span, the next to be placed in the center of each span.

A control panel which shall include circuit breakers and photocell with control board to

sense the day light and switches the lights ON during dark/night hours.

We recommend brackets to fix and hold suggested LED lights components.

Technical specification:

Project 

Qty 

Item Description 

Unit 

Estimated 

Price (US$)

Outdoor 

Lighting 

Outdoor LED street lighting Fixture

150 Watts outdoor LED street lighting Fixture 

LED 

Lamps to 

Fallujah 

Bridge   

Input Voltage: 85 ‐ 265 Volt, 50,60 HZ 

Beam Angle: 90 – 120

High Power LED 100 to 120 Lumen/watt

Light Color: Warm White (2700 K ‐ 3200 K)

Power Factor > 85%, CRI > 70% 

Body is made of durable die‐casting aluminum alloy 

treated with grey color powder anti‐corrosive coating, 

heat resistance silicon rubber sealing prevents from rain 

and dust IP 65, CE and Rohs Certificates 

Bracket 

Galvanized Metal Bracket

1.5" DIA

50‐75 cm length

Including junction fuse box, cables and all needed 

accessories. 

Control Panel (to be installed on one of bridge ends)  Surface distribution panel board 40x30x20 cm

IP 65, completed with contactor 4 poles 25 Ampere/AC3, 

2 poles circuit breaker 2x40 Ampere/3KA, photocell (that 

sense dark night from day light and switches the lighting 

ON/OFF accordingly) also all needed cables and 

accessories for adequate installation. 

4. Traffic signaling

We recommend the use of simple standard road traffic control, where each start of the bridge from both ends shall possess its lighting traffic signaling to control the flow of vehicles from one side to other side for both directions, we recommend to extend and adjust the required timing control for changing from red to green or (green to red) to suitable time taking into account the required time for vehicle to cross the total length of the bridge from one end to the other end.

Technical Description

Item description QTY Unit estimated price in USD

RED-YELLOW-GREEN LED TRAFFIC LIGH (complete with control box.)

Standard Version includes cobweb style diffuser lens for wide angle multi-purpose indoor/outdoor use with visibility up to 200 Meters. Gloss Black or Safety Yellow polycarbonate case. Removable aluminum cut-away style visors. Included L Brackets mount easily in either vertical or horizontal applications. Low Power all LED construction insures long life, low cost of operation and no bulbs to change .Screw terminal strip for easy wiring control switching. Universal AC input, 120-240 VAC 50/60Hz, 8W maximum per module.

5. Communication cable

During site visits it was noticed that, a duct (Ductile pipe 150mm dia.) running from start to end of the bridge on right hand side of end near Fallujah city ,it contains old telephone communications cable for land exchange , at the bridge end near old hospital ,the cable was out of service and abandoned .  Our suggestion is to keep the requirement for the cable duct, as it might it be needed in the future and compensate the broken Ductile pipe 150mm dia. of the fallen span with other damaged pipe parts of other spans with total length about 80 meter. And leave the specs of the required cable to future if required by local communication authorities at Fallujah city.