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Performance-Based Topology Optimization of Main Steel Girders in Composite Bridges with Multi-Criteria Environmental Sustainability Evaluation

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Performance-Based Topology Optimization of Main Steel Girders in Composite Bridges with Multi-Criteria Environmental Sustainability Evaluation

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Department of Mechanical Engineering, Hellenic Mediterranean University, Estavromenos, 71410 Heraklion, Crete, Greece
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Received: 10 July 2026 Revised: 26 August 2026 Accepted: 07 September 2026 Published: 10 September 2026

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© 2026 The authors. This is an open access article under the Creative Commons Attribution 4.0 International License (https://creativecommons.org/licenses/by/4.0/).

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Intell. Sustain. Manuf. 2026, 3(2), 10021; DOI: 10.70322/ism.2026.10021
ABSTRACT: The rising need for economical and ecologically friendly bridges calls for practical solutions that do not compromise the strength, utility, and safety of the structures. The steel-concrete bridge system uses steel girders that carry most of the weight. Thus, an optimal arrangement of girders is necessary for structural efficiency and economic advantage. This study investigates the structural optimization of steel main girders for composite bridges to obtain optimum structural weight and economy. To investigate the coupled behavior of steel girders and concrete decks under realistic conditions, Finite Element Modeling (FEM) is used. In this approach, alternative sizes or configurations for the steel girder are evaluated to predict tensile and compressive stresses as well as deflections. This involves a comparison between the material savings and cost benefits of optimized or conventional designs/configurations. The optimization approaches used in designing composite bridges seem effective at reducing steel mass without affecting bridge performance in terms of stresses and deflections. This study shows that cross-sectional and topology optimization result in a bridge that is more economical, using less steel than previous bridges. Optimization techniques are suggested for designing and building bridges, especially large-scale projects, because of their importance in providing cost-effective and energy-efficient solutions.
Keywords: Structural design; Design constraints; Evolutionary algorithms; Sustainable design; Environmental design; Material efficiency; Optimization
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