Square hollow section (SHS) T-joints with concrete-filled chords subjected to in-plane fatigue loading in the brace

In recent years, there has been an increased use of concrete-filled composite tubular joints in bridge construction. The reliability of these joints under fatigue therefore need to be investigated to avoid any catastrophic failures. In this paper, hollow section T-joints made up of square hollow section (SHS) chords and braces are investigated. The chords of the SHS–SHS T-joints were concrete-filled thereby forming welded composite tubular T-joints. The SHS–SHS T-joints with concrete-filled chords were strain gauged and tested under static loading to determine stress concentration factors (SCFs) at hot spot locations, where cracks are likely to propagate. Fatigue tests of the welded composite joints were also carried out under cyclic in-plane bending in the brace to obtain stress range vs. number of cycles (S–N) data. The maximum stress concentration factor (SCF) at hot spot locations in a welded composite tubular T-joint was found to be generally lower than the maximum SCF in an empty (or called unfilled) hollow section SHS–SHS T-joint. Fatigue failure in welded composite tubular T-joints occurred through the initiation and propagation of cracks at weld toes in either the chord or brace member, with the majority of tests exhibiting the first visual crack at weld toes in the chord. The welded composite tubular T-joints were found to have better fatigue strength compared to the empty hollow section SHS–SHS T-joints. Design rules are recommended for the SHS–SHS T-joints with concrete-filled chords through analysis of fatigue test data using the hot spot stress method.