Symmetry in Stress Distribution: Elastic–Plastic Behavior of Rib Plates and Rib-to-Deck Weld Root Performance in Steel Orthotropic Bridge Decks

This study investigates the mechanical behavior and fatigue performance of orthotropic steel bridge decks, with a focus on rib-to-deck welded connections and the impact of geometric symmetry on stress distribution. Two full-scale models with full-penetration butt welds were tested under static compression loads, yielding failure forces of 27 kN (experimental) and 26 kN (analytical), with only a 3% difference. Finite element simulations using ANSYS 16.1 validated these results and enabled parametric studies. Rib plate thicknesses ranging from 5 mm to 9 mm were analyzed to assess their influence on stress distribution and deformation. The geometric ratio h′/tr, which reflects the symmetry of the trapezoidal rib web, was found to be a critical factor in stress behavior. At h′/tr = 38 (tr = 7 mm), compressive and tensile stresses are balanced, demonstrating a symmetric stress field; at h′/tr = 33 (tr = 8 mm), and fatigue performance at the RDW root drops by 47%. Increasing h′/tr improves fatigue life by increasing the number of load cycles to failure. Stress contours revealed that compressive stress concentrates in the rib plate above the weld toes, while tensile stress localizes at the RDW root. The study highlights how symmetric geometric configurations contribute to balanced stress fields and improved fatigue resistance. Multiple linear regression analysis (SPSS-25) produced predictive equations linking stress values to applied load and geometry, offering a reliable tool for estimating stress without full-scale simulations. These findings underscore the importance of optimizing h′/tr and leveraging structural symmetry to enhance resilience and fatigue resistance in welded joints. This research provides practical guidance for improving the design of orthotropic steel bridge decks and contributes to safer, longer-lasting infrastructure.