A novel copula-based probabilistic model is proposed to establish the temperature difference analysis model for a long-span suspension bridge’s steel box girder. The key idea is to express a two-dimensional function of the temperature difference in flat steel box girder by using copulas. The maximum and minimum values of daily temperature difference model was developed using long-terms structural health monitoring data. Then, the correlation between adjacent temperature differences is investigated using five types of copulas. Akaike information criterion (AIC) is used to select an optimal model from five types of copulas, and the optimal joint function (two-dimensional function) for steel box girder’s temperature difference is established. Finally, the structure’s temperature gradient model is extrapolated for the service life of the structure by using Monte Carlo method. Moreover, this paper discusses the temperature gradient models using five types of common copulas and four types of time-varying copulas. The result shows that the t-copula is the optimal function to build the two-dimensional functions for steel box girder’s temperature difference, and the temperature model along the transverse direction can offer useful information that is not available in the design codes.

Residual stresses are an inevitable result of the welded fabrication process of corrugated steel webs (CSWs), resulting in structures with high and unpredictable stress fields, causing unexpected failures. The residual stress field is affected by structural parameters and the welding path of CSWs. This study proposes the welding process simulation method for CSWs with element birth and death technology. The optimization design method of heat source parameters is proposed. The feasibility of the simulation method is verified by comparing the numerical results with the experimental results of relevant literature. As a part of the study, a comparison of residual stress fields upon cooling welded CSWs with bending angles of 30, 45, and 60 degrees is presented. Thereafter, the effect of two types of single-sided welding paths and double-sided welding construction processes on residual stress distribution is discussed. Generally, the study results have shown that the equivalent residual stress near the weld reaches the maximum 344 MPa, which is very close to the Q345 steel yield strength. The size of the bending angle has no major effect on the residual stress distribution pattern, but it influences the residual stress value at the bending position. The residual stress at the bending position increases with the bending angle of CSWs. Different welding paths significantly impact the residual stress of the weld toe, and selecting a reasonable welding path can effectively reduce the residual stress value by 20 to 40 MPa.

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