Full-Scale Test and Finite Element Modeling of a 30 m Precast Concrete Segmental T-Girder with Epoxy Steel Shear-Keyed Joints

The joint represents a critical component in precast concrete segmental bridges (PCSBs), playing an essential role in transferring shear stress. The efficacy of steel shear keys in comparison to conventional concrete tooth keys has been proven in terms of their shear transfer capability. In this study, a novel design using ultra-high-performance concrete (UHPC) to replace conventional concrete around the steel shear keys was proposed. A 30 m span precast concrete segmental T-girder with epoxy steel shear-keyed joints was fabricated to evaluate the effectiveness of the joint system. Experimental measurements included crack development, load–deflection response, and strain distribution. Furthermore, a finite element (FE) model was developed and validated with the experimental results. The results indicate that the epoxy steel shear-keyed joints effectively transmitted shear stress between segments, with the girder achieving an ultimate load of 1750 kN and a ductile flexural failure mode. The validated FE model accurately captured the critical characteristics of the structure. Finally, an effective calculation method was introduced to predict the ultimate load.