Abstract -Box girder bridges are widely used for long-span constructions due to their high strength-to-weight ratio and structural efficiency. A fundamental component in these bridges is the shear key which allows for effective transfer of loads between bridge segments and upholds the overall structural performance through the different load cases. Overlapping shear keys are becoming increasingly popular because they greatly enhance inter-segment connections, which decrease relative displacements. This paper presents an in-depth analysis of and design for rehabilitation of overlapping shear keys situated within box girder bridges, using successfully utilized finite element analysis software, ANSYS. The analysis investigates the modeling of shear keys surrounded by concrete segments with realistic loading conditions to analyze stress distribution, deflection, and relative failure modes. The research tests different reinforcement patterns that assess reasonable design values that are beneficial to performance and longevity of the structural member. The paper examines how different configurations of reinforcement detailing vastly improve the shear capacity and overall integrity of the elements in place. This research provides a good and strong technical guide for engineers and designers to explore reinforced designs for overlapping shear keys, which will lead to safer and more durable bridge structures.

Keywords:Box Girder Bridges, Shear Keys, Overlapping Shear Keys, Reinforcement Design, Finite Element Analysis (FEA), ANSYS.

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1. Sheng X, Xiao J, Guo H, Zhang H, Liu C, Ma K. Modelling and non-linear analysis of beam-elements in reinforced concrete Vierendeel sandwich plates considering nodal stiffness domain effects. Lat Am J Solids Struct. 2024;21(6): e8071. https://doi.org/10.1590/1679-78258071.
2. Liu J, Huang X, Chen J, Wu Q. Effect of shear deformation at segmental joints on the short-term deflection of large-span cantilever cast prestressed concrete box girders. Buildings. 2023 Jan 12;13(1):219.
3. Xu F, Cheng Y, Wang K, Zhou M. Transverse analysis of box girders with corrugated steel webs. Buildings. 2024 Feb 21;14(3):574.
4. Dhar A, Mazumder M, Chowdhury M, Karmakar S. Effect of skew angle on longitudinal girder (support shear, moment, torsion) and deck slab of an IRC skew bridge. Indian Concr J. 2013 Dec;87(12):46–52.
5. Jaggerwal H, Bajpai Y. Effects of skewness on three span reinforced concrete T girder bridges. Int J Comput Eng Res. 2014;04(8):2250–3005.
6. Pressmair N, Kromoser B. A contribution to resource-efficient construction: design flow and experimental investigation of structurally optimised concrete girders. Eng Struct. 2023 Apr 15; 281:115757.
7. Agarwal P, Singh DK. Parametric study on prestressed skewed box-girder bridge. Adv Bridge Eng. 2023 Jul;4(1):12.
8. Al-Rousan R, Alhassan M, Ababneh A. Simulating the response of CFRP strengthened shear-keys in composite concrete bridges. Mater Des. 2016 Jan 15;90:733–44.
9. Patidar D, Rahul Sharma A. Structural analysis of box girder bridge structure. 2023;10(12):117–121.
10. John S, Prasad R. An overview on box girder bridges. Int Res J Eng Technol. 2017;4(1).
11. Gede A, Khedikar PA. Design of reinforcement of overlapping shear keys in bridges. 2022;9(6):186–193.
12. Khedikar PA, Gaikwad T, College P. Design of reinforcement of overlapping shear keys in bridges. 2022;03.
13. V NY, P PD. Performance analysis of box girder using ANSYS software. Int J Innov Res Sci Eng Technol. 2017;6(12):22408–22413.
14. Treacy MA, Brühwiler E. A direct monitoring approach for the fatigue safety verification of construction joint details in an existing post-tensioned concrete box-girder bridge. Eng Struct. 2015 Apr;88:189–202.
15. Ni X, Anselme AO, Wang G, Xing Y, Xu R. Experimental investigation of shear keys for adjacent precast concrete box beam bridges. Materials (Basel). 2022 Feb 16;15(4):1459.
16. Wang X, Miao C, Wang X. Prediction analysis of deflection in the construction of composite box-girder bridge with corrugated steel webs based on MEC-BP neural networks. Structures. 2021 Aug;32:691–700.
17. Shoukry ME, Ebeido TI, Mahmoud ZI, Mohamed HS. Nonlinear analysis of reinforced concrete slab-on-girder bridges with and without intermediate diaphragms. Alex Eng J. 2025 Jun;124:422–34.
18. Sheng X, Chen Z, Zheng W, Xu H. Time-varying solar radiation-induced non-uniform temperature distribution of steel-concrete composite box girder-ballastless track system. Case Stud Therm Eng. 2023 Mar;43:102750.
19. Kralj J, Gubeljak N, Glodež S, Kramberger J. Numerical investigation of imperfection-induced secondary bending stresses in box girders. Structures. 2025 Sep;79:109477.
20. Ren Y, Cheng W, Wang Y, Chen Q, Wang B. Distortional analysis of simply supported box girders with inner diaphragms considering shear deformation of diaphragms using initial parameter method. Eng Struct. 2017 Aug 15;145:44–59.
21. He J, Wang S, Liu Y, Lyu Z, Li C. Mechanical behavior of a partially encased composite girder with corrugated steel web: interaction of shear and bending. Engineering. 2017 Dec;3(6):806–16.
22. Zhang G, Zhao X, Lu Z, Song C, Li X, Tang C. Review and discussion on fire behavior of bridge girders. J Traffic Transp Eng (Engl Ed). 2022 Jun;9(3):422–46.
23. Ji W, Shao T. Finite element model updating for improved box girder bridges with corrugated steel webs using the response surface method and fmincon algorithm. KSCE J Civ Eng. 2021 Feb;25(2):586–602.
24. Nguyen DD. Optimization of box girder bridge widening techniques: reinforced rib vs. strut solutions. Appl Eng Sci. 2025 Jun;22:100228.

Abstract -Box girder bridges are widely used for long-span constructions due to their high strength-to-weight ratio and structural efficiency. A fundamental component in these bridges is the shear key which allows for effective transfer of loads between bridge segments and upholds the overall structural performance through the different load cases. Overlapping shear keys are becoming increasingly popular because they greatly enhance inter-segment connections, which decrease relative displacements. This paper presents an in-depth analysis of and design for rehabilitation of overlapping shear keys situated within box girder bridges, using successfully utilized finite element analysis software, ANSYS. The analysis investigates the modeling of shear keys surrounded by concrete segments with realistic loading conditions to analyze stress distribution, deflection, and relative failure modes. The research tests different reinforcement patterns that assess reasonable design values that are beneficial to performance and longevity of the structural member. The paper examines how different configurations of reinforcement detailing vastly improve the shear capacity and overall integrity of the elements in place. This research provides a good and strong technical guide for engineers and designers to explore reinforced designs for overlapping shear keys, which will lead to safer and more durable bridge structures.

Keywords:Box Girder Bridges, Shear Keys, Overlapping Shear Keys, Reinforcement Design, Finite Element Analysis (FEA), ANSYS.

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.

1. Sheng X, Xiao J, Guo H, Zhang H, Liu C, Ma K. Modelling and non-linear analysis of beam-elements in reinforced concrete Vierendeel sandwich plates considering nodal stiffness domain effects. Lat Am J Solids Struct. 2024;21(6): e8071. https://doi.org/10.1590/1679-78258071.
2. Liu J, Huang X, Chen J, Wu Q. Effect of shear deformation at segmental joints on the short-term deflection of large-span cantilever cast prestressed concrete box girders. Buildings. 2023 Jan 12;13(1):219.
3. Xu F, Cheng Y, Wang K, Zhou M. Transverse analysis of box girders with corrugated steel webs. Buildings. 2024 Feb 21;14(3):574.
4. Dhar A, Mazumder M, Chowdhury M, Karmakar S. Effect of skew angle on longitudinal girder (support shear, moment, torsion) and deck slab of an IRC skew bridge. Indian Concr J. 2013 Dec;87(12):46–52.
5. Jaggerwal H, Bajpai Y. Effects of skewness on three span reinforced concrete T girder bridges. Int J Comput Eng Res. 2014;04(8):2250–3005.
6. Pressmair N, Kromoser B. A contribution to resource-efficient construction: design flow and experimental investigation of structurally optimised concrete girders. Eng Struct. 2023 Apr 15; 281:115757.
7. Agarwal P, Singh DK. Parametric study on prestressed skewed box-girder bridge. Adv Bridge Eng. 2023 Jul;4(1):12.
8. Al-Rousan R, Alhassan M, Ababneh A. Simulating the response of CFRP strengthened shear-keys in composite concrete bridges. Mater Des. 2016 Jan 15;90:733–44.
9. Patidar D, Rahul Sharma A. Structural analysis of box girder bridge structure. 2023;10(12):117–121.
10. John S, Prasad R. An overview on box girder bridges. Int Res J Eng Technol. 2017;4(1).
11. Gede A, Khedikar PA. Design of reinforcement of overlapping shear keys in bridges. 2022;9(6):186–193.
12. Khedikar PA, Gaikwad T, College P. Design of reinforcement of overlapping shear keys in bridges. 2022;03.
13. V NY, P PD. Performance analysis of box girder using ANSYS software. Int J Innov Res Sci Eng Technol. 2017;6(12):22408–22413.
14. Treacy MA, Brühwiler E. A direct monitoring approach for the fatigue safety verification of construction joint details in an existing post-tensioned concrete box-girder bridge. Eng Struct. 2015 Apr;88:189–202.
15. Ni X, Anselme AO, Wang G, Xing Y, Xu R. Experimental investigation of shear keys for adjacent precast concrete box beam bridges. Materials (Basel). 2022 Feb 16;15(4):1459.
16. Wang X, Miao C, Wang X. Prediction analysis of deflection in the construction of composite box-girder bridge with corrugated steel webs based on MEC-BP neural networks. Structures. 2021 Aug;32:691–700.
17. Shoukry ME, Ebeido TI, Mahmoud ZI, Mohamed HS. Nonlinear analysis of reinforced concrete slab-on-girder bridges with and without intermediate diaphragms. Alex Eng J. 2025 Jun;124:422–34.
18. Sheng X, Chen Z, Zheng W, Xu H. Time-varying solar radiation-induced non-uniform temperature distribution of steel-concrete composite box girder-ballastless track system. Case Stud Therm Eng. 2023 Mar;43:102750.
19. Kralj J, Gubeljak N, Glodež S, Kramberger J. Numerical investigation of imperfection-induced secondary bending stresses in box girders. Structures. 2025 Sep;79:109477.
20. Ren Y, Cheng W, Wang Y, Chen Q, Wang B. Distortional analysis of simply supported box girders with inner diaphragms considering shear deformation of diaphragms using initial parameter method. Eng Struct. 2017 Aug 15;145:44–59.
21. He J, Wang S, Liu Y, Lyu Z, Li C. Mechanical behavior of a partially encased composite girder with corrugated steel web: interaction of shear and bending. Engineering. 2017 Dec;3(6):806–16.
22. Zhang G, Zhao X, Lu Z, Song C, Li X, Tang C. Review and discussion on fire behavior of bridge girders. J Traffic Transp Eng (Engl Ed). 2022 Jun;9(3):422–46.
23. Ji W, Shao T. Finite element model updating for improved box girder bridges with corrugated steel webs using the response surface method and fmincon algorithm. KSCE J Civ Eng. 2021 Feb;25(2):586–602.
24. Nguyen DD. Optimization of box girder bridge widening techniques: reinforced rib vs. strut solutions. Appl Eng Sci. 2025 Jun;22:100228.