Abstract Internal stresses or residual stresses in the structural elements are very crucial in carrying out in-service evaluations and fitness-for-purpose assessments. The generation of these internal stresses can occur as result of the fabrication of the steel members, installation sequence or other ad-hoc events such as accidents or impact. The accurate prediction of the internal stresses will contribute towards estimating the integrity state of the structural elements, with respect to their material allowable stresses. This paper investigates the explicit FE based numerical modelling of the ultrasonic based non-destructive technique, utilising the measurable longitudinal critical refracted wave (LCR) and relating these to the internal stresses within the structural elements by the evaluation of the material dependent acoustoelastic factors. The subsurface travel path of the LCR wave inside the structural elements makes it a sub-surface stress measurement technique and the linearised relationship with corresponding internal stresses can be systematically applied repeatedly. The numerical results are compared against laboratory tests data to correlate the findings and to establish modelling feasibility for future proof-of-concepts. It can be concluded from this numerical investigation, that the subsurface ultrasonic LCR wave has great potential to be implemented for in-situ structural residual stress measurements, as compared to other available surface measurements such as strain gauges or x-ray diffraction.