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To determine the distribution characteristics of the residual stress in a transmission tower welded circular tube section fabricated from 690 MPa high-strength steel (HSS), an experimental study using 30 galvanised and non-galvanised 690 MPa HSS specimens was conducted using the sectioning method and the hole-drilling method. Further, the effects of the residual stress measurement method, hot-dip galvanisation and circular diameter-to-thickness ratio on the residual stress were discussed. Finally, two distribution models for galvanised and non-galvanised specimens, and their simplified forms, were established. Comparison with a model of a welded circular tube section composed of normal-strength steel (NSS) showed that, although the maximum tensile residual stress of 690 MPa HSS is consistent with that of NSS, and although both exhibit the desired material yield strength, the maximum compressive residual stress of the HSS specimen is only 57% of that of the NSS specimen.

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