AbstractWelding provides more options than conventional methods for the repair and rehabilitation of existing riveted steel structures. Previous research at HTW Dresden developed welding principles for old mild steels and implemented initial practical applications in rehabilitation. Besides classical limit state analysis, fatigue analysis plays a decisive role in cyclically loaded structures. While extensive research and regulations exist for welded joints in modern structural steels, there is a lack of reliable knowledge on the fatigue strength of welds in old mild steels.Current research systematically investigates structural details typical of repair and reinforcement in steel railway bridges, such as butt joints or stiffeners. Stress conditions are analysed to design and carry out S‐N tests on specimens combining old mild steel with modern structural steel. The aim is to determine the fatigue strength of old mild steel welds compared to modern structural steel welds, assuming proper welding practices. The results are applied in a pilot project (the rehabilitation of the Siemensbahn, a suburban railway line in Berlin), where severe corrosion damage to double‐curved deck plates (buckled plates) requires localised replacement. This enables fast and efficient repairs.
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