Fatigue strength of the joint of steel cantilevers in composite bridges

Box girders with steel cantilevers underneath the deck are frequently used in the design of composite steel bridges. Hereby, the welded joints between the main girder and the transverse system have to endure fatigue loads. Current design specifications for this joint, e.g., a tapering in thickness of the top flanges at the same position of a transition radius, are complex to manufacture and provide a higher fatigue resistance than necessary. This article addresses the optimization of this structural detail, which is realized hundreds of times per structure. Several laboratory tests and numerical simulations were carried out regarding the load‐bearing behavior and the fatigue safety of the cantilevers as double‐T‐sections and as box girders. Additionally, 60 fatigue tests were conducted on small‐scale specimen to classify the resulting simplified design variants in detail categories of the nominal stress concept. As a result, two design recommendations are proposed for the joint at the intersecting top flanges. Moreover, the effect of an unplanned axial misalignment on the fatigue strength of the joint at the bottom flange is quantified.