Complex welding operations in orthotropic steel bridge decks introduce residual stresses near the weld region. To estimate fatigue failure of this type of bridge deck, tensile residual yield stresses are usually assumed around the weld region. However, to estimate the residual stress distribution near a weld connection more precisely, a test setup is developed. The weld connection of a closed longitudinal trapezoidal stiffener with the deck plate of an orthotropic bridge deck is investigated. The incremental hole-drilling technique is used to measure the residual stresses with strain gauge rosettes. Strain gauge rosettes are positioned on the deck plate and on a longitudinal stiffener of the orthotropic steel deck. A small hole is drilled through the center of the strain gauge rosettes and strains are measured at incremental depths. The residual stresses are calculated and based on these experimental measurements a distribution of the residual stresses is obtained. Compressive residual stresses exist near the longitudinal stiffener-to-deck plate weld. On the deck plate, the compressive residual stresses are equal to 60% of the yield strength while the compressive residual stresses on the stiffener are 42% of the yield strength. There are tensile residual stresses on both sides of the weld region. However, more research is necessary to confirm this distribution since it is contradictory to expected stresses in literature.
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