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In order to develop high-strength, high-toughness and high-wear-resistance rails suitable for the development and application of heavy-haul railways.

Based on the trial production of 60 kg·m⁻¹ bainite rails, the Zeiss inverted optical microscope, transmission electron microscope and static hydraulic universal tester were used to test the microstructure and property of rail base metal and welded joints. Meanwhile, a trial laying of rails, wing rails of frogs and switch rails for turnouts was performed to systematically analyze their strength, toughness and wear resistance.

The results show that the base metal of 60 kg·m⁻¹ bainite rail is of a uniform microstructure, with a carbide-free bainite matrix, a few of stable residual austenite and M/A islands, and it features high hardness, good wear resistance and good strength-toughness balance. The welded joint is of a uniform microstructure and has good properties.

A bainite rail, laid in a curve section of heavy-haul railway is able to serve for 48 months with a gross traffic tonnage of nearly 600 million tons, whose service life is more than one time longer than that of pearlite rail; the service life of the wing rail of frog and the switch rail for turnout with 60 kg·m⁻¹ bainite rails is 3–4 times longer than that with U75V rails, and no serious damage occurs. The bainite rails also have strong peeling and spalling resistance.

This study aims to research the development trend, research status, research results and existing problems of the steel–concrete composite joint of railway long-span hybrid girder cable-stayed bridge.

Based on the investigation and analysis of the development history, structure form, structural parameters, stress characteristics, shear connector stress state, force transmission mechanism, and fatigue performance, aiming at the steel–concrete composite joint of railway long-span hybrid girder cable-stayed bridge, the development trend, research status, research results and existing problems are expounded.

The shear-compression composite joint has become the main form in practice, featuring shortened length and simplified structure. The length of composite joints between 1.5 and 3.0 m has no significant effect on the stress and force transmission laws of the main girder. The reasonable thickness of the bearing plate is 40–70 mm. The calculation theory and simplified calculation formula of the overall bearing capacity, the nonuniformity and distribution laws of the shear connector, the force transferring ratio of steel and concrete components, the fatigue failure mechanism and structural parameters effects are the focus of the research study.

This study puts forward some suggestions and prospects for the structural design and theoretical research of the steel–concrete composite joint of railway long-span hybrid girder cable-stayed bridge.

This research addresses the diverse characteristics of existing railway steel bridges in China, including variations in construction age, design standards, structural types, manufacturing processes, materials and service conditions. It also focuses on prominent defects and challenges related to heavy transportation conditions, particularly low live haul reserves and severe fatigue problems.

The study encompasses three key aspects: (1) Adaptability assessment: It begins with assessing the suitability of existing railway steel bridges for heavy-haul operations through comprehensive analyses, experiments and engineering applications. (2) Strengthening: To combat frequent crack defects in the vertical stiffener end structure of girder webs, fatigue performance tests and reinforcement scheme experiments were conducted. These experiments included the development of a hot-spot stress S-N curve for this structure, validating the effectiveness of methods like crack stop holes, ultrasonic hammering and flange angle steel. (3) Service life extension: Research on the cruciform welded joint structure (non-fusion transfer type) focused on fatigue performance over the long life cycle. This led to the establishment of a fatigue S-N curve, enhancing Chinese design codes.

The research achieved several significant outcomes: (1) Successful implementation of strengthening and retrofitting measures on a 64-m single-span double-track railway steel truss girder on an existing heavy-duty line. (2) Post-reinforcement, a substantial 26% to 32% reduction in live haul stress on bridge members was achieved. (3) The strengthening and retrofitting efforts met design expectations, enabling the bridge to accommodate vehicles with a 30-ton axle haul on the railway line.

This research systematically tackles challenges and defects associated with Chinese existing railway steel bridges, providing valuable insights into adaptability assessment, strengthening techniques and service life extension methods. Furthermore, the development of fatigue S-N curves and the successful implementation of bridge enhancements have practical implications for improving the resilience and operational capacity of railway steel bridges in China.