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Front. Struct. Civ. Eng.    2022, Vol. 16 Issue (1) : 24-44    https://doi.org/10.1007/s11709-021-0794-9
REVIEW
Materials-oriented integrated design and construction of structures in civil engineering—A review
Xing MING1, John C. HUANG2, Zongjin LI1()
1. Institute of Applied Physics and Materials Engineering, University of Macao, Macao SAR 999078, China
2. CHC Engineering, LLC, Fairfax, VA 20030, USA
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Abstract

Design is a goal-oriented planning activity for creating products, processes, and systems with desired functions through specifications. It is a decision-making exploration: the design outcome may vary greatly depending on the designer’s knowledge and philosophy. Integrated design is one type of design philosophy that takes an interdisciplinary and holistic approach. In civil engineering, structural design is such an activity for creating buildings and infrastructures. Recently, structural design in many countries has emphasized a performance-based philosophy that simultaneously considers a structure’s safety, durability, serviceability, and sustainability. Consequently, integrated design in civil engineering has become more popular, useful, and important. Material-oriented integrated design and construction of structures (MIDCS) combine materials engineering and structural engineering in the design stage: it fully utilizes the strengths of materials by selecting the most suitable structural forms and construction methodologies. This paper will explore real-world examples of MIDCS, including the realization of MIDCS in timber seismic-resistant structures, masonry arch structures, long-span steel bridges, prefabricated/on-site extruded light-weight steel structures, fiber-reinforced cementitious composites structures, and fiber-reinforced polymer bridge decks. Additionally, advanced material design methods such as bioinspired design and structure construction technology of additive manufacturing are briefly reviewed and discussed to demonstrate how MIDCS can combine materials and structures. A unified strength-durability design theory is also introduced, which is a human-centric, interdisciplinary, and holistic approach to the description and development of any civil infrastructure and includes all processes directly involved in the life cycle of the infrastructure. Finally, this paper lays out future research directions for further development in the field.
Keywords integrated design and construction      fiber-reinforced concrete      fiber-reinforced polymer      light-weight steel structures      digital fabrication      composites     
Corresponding Author(s): Zongjin LI   
Just Accepted Date: 23 December 2021   Online First Date: 14 February 2022    Issue Date: 07 March 2022
 Cite this article:   
Xing MING,John C. HUANG,Zongjin LI. Materials-oriented integrated design and construction of structures in civil engineering—A review[J]. Front. Struct. Civ. Eng., 2022, 16(1): 24-44.
 URL:  
https://academic.hep.com.cn/fsce/EN/10.1007/s11709-021-0794-9
https://academic.hep.com.cn/fsce/EN/Y2022/V16/I1/24
Fig.1  The intertwined relationship between materials and structures [18].
Fig.2  Schematic illustration of the concepts of MIDCS in civil engineering (Reprinted from Cement and Concrete Research, 141, Zuo Y, Ye G, GeoMicro3D: A novel numerical model for simulating the reaction process and microstructure formation of alkali-activated slag, 106328, Copyright 2021, with permission from Elsevier). Notes: the images from quantum to continuum are from Refs. [21–24]; the images for structural engineering are from Wikipedia. All these images are reproduced by the authors.
series part presence (%) characteristics functions
physical composition bark 7–20 A dead and corky outer layer with variable thickness and a growth inner layer √ Label of tree species√ Medicinal material√ Origin of fibers and thermal insulation material
cambium N/A A thin layer of cells with meristematic ability between bark and xylem √ Origin of bark and xylem
xylem N/A Low moisture, dark, hard, dead, and high-density for heartwood; opposite characteristics for sapwood √ Heartwood provides structural strength and is resistant to decay; the origin of timber√ Sapwood is the storehouse for starches and a pipeline for sap, and it is not durable
pith N/A The central core of the tree with variable structure, size, and color √ No engineering applications
chemical composition cellulose N/A A linear polymer with highly ordered strands (also called fibrils) √ Source of large structural elements and cell walls of wood fibers
lignin 23–33 in softwood, and 16–25 in hardwood by weight An intercellular material that glues tubular cells together √ Source of longitudinal shear strength
hemicellulose 15–20 in softwood and 20–30 in hardwood A sugar-based material with polymeric units √ Cross-links cellulose fibrils, strengthening cell walls
extractives 5–30 Nonstructural elements containing coloring, essential oils, etc. N/A
minerals 0.1–3 Calcium, potassium, etc. N/A
Tab.1  Compositions, characteristics, and functions of different parts of timber [1,27]
Fig.3  (a) Levels present in timber; (b) variability of timber at different scales [26] (Reprinted from Construction and Building Materials, 97, Marzi T, Nanostructured materials for protection and reinforcement of timber structures: A review and future challenges, 119–130, Copyright 2015, with permission from Elsevier).
connection characteristic function
dougong elastic and self-locking when loaded damping effect
mortise and tenon semi-rigid damping effect
column base flexible damping and isolation effects
Tab.2  Timber connections and related functions for seismic resistance [28,30,36,39,40]
Fig.4  Typical ancient timber structures: (a) Yingxian Wood Pagoda [35]; (b) Feiyun Pavilion [35]; (c) the Imperial Palace in China; (d) the Imperial Palace in Japan (Reprinted from Construction and Building Materials, 105, Qiao G F, Li T Y, Chen Y F, Assessment and retrofitting solutions for an historical wooden pavilion in China, 435–447, Copyright 2016, with permission from Elsevier).
Fig.5  Components of an ancient timber hall-style structure [38] (Reprinted from Engineering Structures, 156, Chen J Y, Li T Y, Yang Q S, Shi X W, Zhao Y X, Degradation laws of hysteretic behaviour for historical timber buildings based on pseudo-static tests, 480–489, Copyright 2018, with permission from Elsevier).
Fig.6  Modern timber structures: (a) timber roof; (b) National Welsh Assembly; (c) Kamppi Chapel of Silence in Helsinki [26] (Reprinted from Construction and Building Materials, 97, Marzi T, Nanostructured materials for protection and reinforcement of timber structures: A review and future challenges, 119–130, Copyright 2015, with permission from Elsevier).
Fig.7  Typical masonry arch structures: (a) and (b) are cross vaults in Scotland [59] (Reprinted from Engineering Structures, 180, Bertolesi E, Adam J M, Rinaudo P, Calderón P A, Research and practice on masonry cross vaults––A review, 67–88, Copyright 2019, with permission from Elsevier); (c) masonry arch bridge in France; (d) stone arch bridge in France.
Fig.8  The Zhaozhou Bridge (image from Wikipedia).
rank name main span (m) year opened country main materials image
1 Russky Bridge 1104 2012 Russia RC bridge tower and galvanized PSS cables
2 Hutong Yangtze River Bridge 1092 2020 China RC bridge tower
3 Sutong Yangtze River Bridge 1088 2008 China RC bridge tower and steel box girder
4 Stonecutters Bridge 1018 2009 China Concrete and stainless-steel skin for the tower, steel for the main span, concrete for side spans
5 Edong Yangtze River Bridge 926 2010 China RC bridge tower, steel box girder, and galvanized PSS cables
Tab.3  Top five cable-stayed bridges in the world
rank name main span (m) year opened country main materials image
1 Akashi Kaikyō Bridge 1991 1998 Japan Steel bridge tower, steel truss, and high strength galvanized cables
2 Yangsigang Yangtze River Bridge 1700 2019 China RC bridge tower, steel truss, and high strength galvanized PPWS cables
3 Nansha Bridge 1688 2019 China Steel box girder and high strength galvanized cables
4 Xihoumen Bridge 1650 2009 China RC bridge tower, steel box girder, and high strength galvanized PPWS cables
5 Great Belt Bridge 1624 1998 Denmark RC bridge tower, steel box girder, and steel cables
Tab.4  Top five suspension bridges in the world.
Fig.9  Cold-formed steel: (a) effects of cold-forming; (b) steel coils before cold-forming; (c) steel stud coming out of a roll-forming machine; (d) steel floor joist end connection; (e) pre-punched and stiffened hole in steel joist; (f) steel stud wall and roof framing. Notes: Components shown on (c), (d), (e), and (f) are all produced in CFS mobile factories. See Fig. 10 for the schematic diagram of a CFS mobile factory.
Fig.10  Schematic diagram of digital design, fabrication, and construction of a cold-formed steel building through a CFS mobile factory.
Fig.11  Various buildings with ECC coupling beams in Japan: (a) 27 story Glorio-Tower; (b) 41 story Nabule Yokohama Tower; (c) 60 story Kitahama Tower [10] (Reprinted by permission from Springer Nature Customer Service Centre GmbH: Springer Nature, Springer eBook, Applications of Engineered Cementitious Composites (ECC), Li V C, 2019).
Fig.12  Examples of UHPFRCC bridges: (a) Cat Point Creek Bridge in the United States; (b) Sherbrooke Overpass in Canada; (c) Wild Bridge in Austria; (d) Mars Hill Bridge in the United States; (e) Celakovice Pedestrian Bridge in the Czech Republic; (f) Peace Bridge in South Korea [87] (Reprinted from Construction and Building Materials, 186, Zhou M, Lu W, Song J, Lee G C, Application of ultra-high performance concrete in bridge engineering, 1256–1267, Copyright 2018, with permission from Elsevier).
Fig.13  FRP products for civil infrastructures [99].
refurbishment new construction
Ø minimize traffic disruption Ø low initial costs
Ø minimize application time Ø low maintenance costs
Ø low initial costs Ø short construction time
Ø high long-term performance Ø minimize traffic disruption
Ø low maintenance costs Ø minimize life-cycle costs
Ø minimize environmental impact
Tab.5  Priorities of various demands on using FRP to refurbish a damaged bridge and construct a new bridge [93]
Fig.14  Sandwich bridge decks: (a) foam core FRP; (b) sinusoidal core FRP [100] (Reprinted from Composite Structures, 92(7), Chen A, Davalos J F, Strength evaluations of sinusoidal core for FRP sandwich bridge deck panels, 1561–1573, Copyright 2010, with permission from Elsevier).
Fig.15  3DPC structures: (a) 3DPC wall [119] (Reprinted from Materials & Design, 100, Gosselin C, Duballet R, Roux P, Gaudillière N, Dirrenberger J, Morel P, Large-scale 3D printing of ultra-high performance concrete—A new processing route for architects and builders, 102–109, Copyright 2016, with permission from Elsevier); (b) 3DPC arch bridge [104] (Reprinted from Composites. Part A: Applied Science and Manufacturing, 125, Zhang J, Wang J, Dong S, Yu X, Han B, A review of the current progress and application of 3D printed concrete, 105533, Copyright 2019, with permission from Elsevier); (c) 3DPC Bloom Pavilion at UC Berkeley.
Fig.16  Conversion of chemical influence to mechanical effect [124] (with permission).
Fig.17  Regularity of concrete structure performance as a function of time [124] (with permission).
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