Bridging the gap between mathematical optimization and structural engineering: Design, experiments and numerical simulation of optimized concrete girders

Concrete, as the most widely used construction material, is associated with a high environmental impact. Within the present study, structural optimization is the method of choice to counter this issue. The entire process, from optimization, to design, experiments and numerical simulation is outlined. Embedded in the framework of a design competition (Concrete Girder Optimization Competition 2021), a bridge between structural engineering and mathematical optimization is demonstrated. Two design concepts for optimized concrete girders, one with internal and one with external reinforcement, yet both based on strut-and-tie modeling, were investigated. Within the boundaries of the competition, several conclusions can be drawn: The results indicate the importance of an adequate structural interpretation of topology optimization results to obtain satisfying structural performance. The environmental evaluation outlines that the reinforcement mass has a substantial share in the total Global Warming Potential. A successful numerical re-simulation of selected girders can serve as a modeling base for other researchers. Compared to a conventionally designed girder an increase in resource efficiency, measured by load-carrying capacity versus environmental impact, of more than 30% was achieved.