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Splicing quality issues are commonly observed in field-welded steel box girder segments exposed to ambient environmental temperatures. To investigate the effect of splicing temperature difference (STD) and improve construction quality, finite-element models were developed to simulate the welding–splicing process of these segments. The formation mechanism of the STD and the effect of key parameters were investigated using the numerical model. The results show that temperature field variations during the welding–splicing process induced structural deformation. The boundary conditions of the steel box girders were changed by the welding process. The STD effect arose when thermal deformation was locked within the spliced segments. Temperature variations, boundary conditions, segment length and welding sequences significantly affect the STD in field-welded steel box girders.

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