Numerical modeling approaches are favored for performing long-term analyses of continuous prestressed concrete rigid-frame (CPCR) bridges due to the complexity and high cost of experimental testing on such structures. In this study, a refined numerical modeling approach is first presented and validated by comparing the field monitor data of an existing long-span CPCR bridge in China. Then, long-term deflection analysis—considering box girder cracks, concrete creep, joint damage behavior and prestress—is conducted based on the proposed refined modeling approach. It is found that the time-dependent loss of longitudinal prestress has the most significant influence on the long-term structural stiffness, while joint damage between different segments has limited impact on overall structural performance, especially for large-span bridge cases. The local stress distribution is significantly influenced by typical damage, albeit with a different scope of impact. Therefore, targeted reinforcement has to be performed to achieve satisfactory repair results under different damage conditions.

Due to factors such as casting, mold making, and construction errors, the actual size of the bridge structure will inevitably deviate from the designed size and dimension, and the amount of deviation between the two volumes is generally random and the location of the deviation is not fixed. However, this phenomenon that occurs in the actual practice has not been paid enough attention within existing studies. From a theoretical point of view, the apparent size of concrete will directly affect the cross-sectional stiffness, especially for statically indeterminate structures. This effect will be further reflected in the internal force and stress distribution of the structure. In addition, the variation of the poured volume of the bridge superstructure can also influence the dead-load effect of the bridge structure. Therefore, the influence of pouring concrete volume deviation (PCVD) on the cross-sectional stiffness of large-span continuous reinforced concrete rigid-frame (CRCR) bridges was first stressed and investigated in this paper. Field data of PCVD were monitored by measuring demolished sections with tools that ensure accuracy, and a sensitivity analysis was conducted to analyze the effect of PCVD on the cross-sectional stiffness at different locations. Statistical analysis of the measured data concluded that PCVD has a significant influence on the internal-force distribution and structural stiffness of the bridge, up to 30%. Finally, a theoretical method that considers the influence of PCVD was proposed based on the field monitoring data and the statistical analysis results.

The dynamic behavior of three-layer composite beams, consisting of concrete slabs and steel beams, is influenced by the structural configuration of each layer as well as the shear connectors. The interlayer shear stiffness in three-layer composite beams governs their global dynamic behavior, while interlayer slippage-induced localized vibration effects represent a key limiting factor in practical applications. Based on the dynamic test results of steel–concrete double-layer composite beams, the feasibility of a finite element solid model for composite beams, which accounts for interlayer shear connectors and beam body characteristics, has been validated. Utilizing identical modeling parameters, an analytical model for the inherent vibration characteristics of three-layer steel–concrete composite beams has been developed. This study encompasses two types of composite beams: concrete–steel–concrete (CSC) and concrete–concrete–steel (CCS). Numerical simulations and theoretical analysis systematically investigated the effects of interface shear connector arrangements and structural geometric parameters on dynamic performance. Research indicates that the natural frequency of steel–concrete three-layer composite beams exhibits a distinct two-stage increasing trend with the enhancement in interlayer shear stiffness. For CSC-type simply supported composite beams, the fundamental vertical vibration frequency increases by 37.82% when achieving full shear connection at both interfaces compared to the unconnected state, while two-equal-span continuous beams show a 38.06% improvement. However, significant differences remain between the fully shear-connected state and theoretical rigid-bonding condition, with frequency discrepancies of 24.69% for simply supported beams and 24.07% for continuous beams. Notably, CCS-type simply supported beams display a 12.07% frequency increase with full concrete-to-concrete connection, exceeding even the theoretical rigid-bonding frequency value. Longitudinal connector arrangement non-uniformity significantly impacts dynamic characteristics, while the transverse arrangement has minimal influence. Among structural parameters, steel flange plate thickness has the most significant effect, followed by concrete slab width and thickness, with steel web thickness having the least impact. Based on the observation that the first-order vertical vibration frequency of three-layer composite beams exhibits a two-stage decreasing trend with an increase in the span-to-depth ratio, it is recommended that the span-to-depth ratio of three-layer steel–concrete composite beams should not be less than 10.

During the stud welding process, residual stresses are inevitably induced due to the significant temperature gradients and associated heterogeneous thermal expansion and contraction. These residual stresses significantly influence the mechanical properties of the welded structure. Quantitative evaluation of the welding residual stress distribution on the steel plate surface was performed using X-ray diffraction (XRD) and the blind-hole method. Results demonstrate that the radial residual stress initially increases and subsequently decreases with increasing distance from the weld ring. The circumferential residual stress is characterized as compressive throughout the measured region, also exhibiting an initial increase, followed by a decrease, and a subsequent increase with greater distance from the weld center. Both radial and circumferential stresses form a compressive stress zone within the weld and its immediate vicinity, with a peak value of approximately 170 MPa. The significant solid-state phase transformations occurring in the weld metal and the adjacent heat-affected zone lead to the development of compressive stresses upon cooling. The compressive stresses observed in the base metal region, far from the weld, are likely attributable to the initial rolling stresses inherent to the steel plate.