Innovative design of long-span steel–concrete composite bridge using multi-material topology optimization

This paper proposes a novel bridge design approach based on multi-material topology optimization, which realizes the process from conceptual design to detailed design, and an innovative bridge form is obtained with the proposed approach. In the present study, the multi-material bi-directional evolutionary structural optimization (MBESO) method, which is developed from the bi-directional evolutionary structural optimization (BESO) method, is used as the algorithm which can effectively handle topology optimization problems involving multiple materials. Since the method assigns two different materials to the tension and compression members in a structure, it is particularly suitable for designing bridge structures composed of steel and concrete. A three-span bridge with a main span of 350 m is used as an example to apply the MBESO method for the topology optimization design, and a set of techniques are introduced, such as the variation of the design domain, the utilization of symmetry, the selection of the non-design domain and the consideration of multiple load cases, to obtain multiple optimization results. By comprehensively studying the functionality, ease of construction, and aesthetic properties, a competitive result is selected as the proposed conceptual design for the bridge, and then a detailed design, including an implementable construction process, is achieved and verified by finite element analysis. The comparison between the proposed bridge and other typical bridge types based on technical and economic indicators clearly shows the obvious advantages of the new type of bridge design. This research work realizes the whole process to obtain the detailed design of a new bridge type from the form-finding with the MBESO method, revealing the considerable value of applying multi-material topology optimization to the design of practical long-span bridges.