<p>This study presents a sequential thermo-mechanical model that incorporates welding numerical computation results as pre-state condition data into a fatigue crack propagation prediction model using high strength low alloy (HSLA) S460 G2 + M for offshore structures. The implementation of FEM residual stresses in prior studies applies the consequence of stresses indirectly to the model by superposition or even neglecting it. The arc welding process was simulated using thermomechanical constitutive theorem, a double ellipsoid heat source model, and an isotropic hardening model based on von Mises yield criteria. Chained simulations were conducted at the weld and heat affected zone (HAZ) using residual stress obtained from previous welding simulations using the virtual crack closure method (VCCT) based on energy release rate with the use of the base material crack parameters. Furthermore, adaptive remeshing algorithms were implemented for singular enrichment on the mesh geometry at nodes adhering to the fracture front. Experiments were conducted using robotic gas metal arc welding process with filler material ER80S-Ni1 and mixed shielding gas Argon-CO₂. The predicted residual stress and distortion were verified with minimal deviation from the welding experimental value. Material constants(C) and slopes (m) were determined for the three weld zones. The life cycle using chained simulation analysis showed a percentage error of up to 12% at HAZ and Weldment and if material parameters of the base material and induced residual of the manufacturing process at suspected crack locations can be defined for modelling fatigue life cycle.</p> Graphical Abstract <p></p>