This paper focuses on a series of new developments on analytical treatment of secondary stress concentration effects caused by the presence of angular and buckling distortions in thin plate structures. The distortion profiles are idealized through a simple mechanics treatment upon which the analytical solution to the stress concentration factor (SCF) induced by secondary bending is further derived. With such approach, the distortion effects on fatigue behaviors can be captured without the need for performing detailed finite element calculations incorporating measured distortions. The applications of these analytical solutions incorporating secondary bending caused by distortions and remote loading are demonstrated by analyzing existing test data obtained on small-scale thin plate butt joints containing local and global angular distortions. By considering the fatigue test data as well as measured distortion data, the use of so calculated SCFs not only enable an effective correlation among simple butt-welded specimens with various forms of angular and axial misalignments, but also between the tested specimens and the 2007 ASME master S-N curve scatter band which contain large-scale fatigue test data with plate thicknesses ranging from 5 mm up to over 100 mm.