Evaluation and retrofit of steel girder shiplap connections

Over time, owners may face challenges with management of bridges with outdated details. One such detail that is no longer used today is the steel girder shiplap connection. These were originally employed to simplify analysis of continuous girders while also moving joints away from the piers, improving longevity of bridge bearings and substructures. Unfortunately, fatigue issues have appeared in these connections resulting in cracking at critical load-carrying locations. In this project, analysis was performed to investigate connection fatigue and strength and retrofit design verification. Results utilizing non-linear analysis showed that while stresses from ultimate loading could adequately redistribute throughout the web, high stress concentrations were created, exacerbating fatigue. Stress calculations for shiplap web details are not well codified or easily assessed with simple hand calculations, so finite element analysis was utilized. Results showed web fatigue life had been exhausted with more cracking expected at other locations, convincing the owner retrofit was necessary even though the bridge was programmed for replacement.