A precast concrete deck-steel beam-connection concrete (PCSC) connector using ultra-high-performance concrete (UHPC) as post-cast concrete has been proposed to enable rapid on-site construction of assembled composite bridges. This paper aims to optimize the structure of PCSC connectors using the finite element (FE) model to maximize material utilization and economic efficiency. A refined FE model comprising the bond degradation at the steel–UHPC interface was developed based on the push-out experimental results of PCSC connectors. The shear mechanism of the PCSC connectors was analyzed. Subsequently, parametric analyses were performed to investigate the effects of stud diameter, height, spacing, and concrete strength on the mechanical properties of PCSC connectors. The results indicate that the bond at the steel–connection concrete interface positively affects the shear bearing capacity and stiffness of the PCSC connectors. When UHPC was used as connection concrete, it improved the bearing capacity by about 20% and the shear stiffness of the stud by about 16% compared with normal concrete, but the ductility was 38% lower. It was also found that increasing the compressive strength of the connection concrete increased the shear strength of specimens. However, when the compressive strength of UHPC exceeded 130 MPa, the additional UHPC strength did not significantly enhance the shear performance of specimens. In order to ensure the effective restraint of the connection concrete to studs, it is recommended that the minimum width and height of the connection concrete (UHPC) be determined based on the minimum horizontal spacing and height of the studs. Specifically, the length-to-diameter ratio of studs is greater than or equal to 3.18, the horizontal spacing of studs can be at least 2.82 d, and the clear distance between the outer stud shank and the edge of the UHPC cannot be less than 30 mm. The results are expected to provide a reference for the engineering design of PCSC connectors and a reference for conventional stud connectors with UHPC.

Assembled steel-composite bridges generally use stud connectors to achieve the connection between the deck slab and the steel main girders. However, the commonly-used cluster studs weaken the integrity of the precast deck slabs and are not conducive to reducing the size of the precast deck slabs. Based on the excellent mechanical performance of UHPC, a precast steel-concrete composite bridge system consisting of precast bridge deck slabs, bonding cavities, and steel girders was proposed in this study. The system was named PSCC (Precast Steel-Concrete Connectors). To verify the applicability of PSCC connectors in engineering, push-out tests and finite element analysis were carried out in this paper to investigate the shear performance and influence parameters of PSCC connectors. The results showed that compared with the full bonding at the steel-UHPC interface, the shear bearing capacity of the specimens with 30% debonded area rate (the ratio of defect area to total interface area) and the shear bearing capacity of the specimens with 60% debonded area rate decreased by 0.35% and 9.74%, the elastic stiffness decreased by 14.86% and 21.72%, and the elastic-plastic stiffness decreased by 1.6% and 12.8%, respectively. When the steel-UHPC percentage of debonded area is less than 30%, the shear resistance of PSCC connectors is affected very little. However, when the steel-UHPC percentage of debonded area is 60%, the shear resistance of PSCC connectors is greatly affected. Therefore, adequate filling of the UHPC connection layer should be ensured in the project. In addition, the PSCC connectors have excellent ductility, their characteristic slip value $S_u$ is much higher than the EC4 specification of 6 mm, and they have better shear performance than conventionally installed stud connectors. According to the results of the parametric analysis, it was found that the failure mode of the PSCC connectors was shear reinforcement fracture when the area ratio of shear reinforcement to stud was less than 1.55, under the premise of the same material strength. On the contrary, the failure mode of PSCC connections was stud fracture. When the transverse spacing of both studs and shear reinforcement is 4d, the PSCC connectors can maintain a high ultimate load capacity while reducing the amount of UHPC in the bonding cavity. Therefore, 4d was chosen as the best spacing for both studs and shear reinforcement.