Numerical validation and optimization of hybrid composite beam hull using multiple failure criteria

•Lack of market usage is noticed for Hybrid Composite beams (HCB) produced by Hillman.•Cost analysis of HCB is conducted which showed FRP is about half of the girder’s price.•Numerical Validation of experimentally tested Knickerbocker HCB is developed to assess FRP material usage.•Quantification of FRP strength ratios concluded 90% of hull areas have a value of 5 to 50.•Alternative optimized design of FRP hull is proposed using GA to revive HCB to market. The number of structurally deficient bridges continues to increase due to corrosion of steel sections and concrete rebar, therefore the replacement of decaying structures and the development of innovative systems have become of high priority to extend the life span of newly built bridges. Hybrid Composite Beam (HCB) produced by Hillman is one of those systems that use a combination of materials i.e., concrete, steel, and Glass Fiber-Reinforced Polymer (GFRP) to integrate each main advantage in a single bridge beam structure. Despite its several apparent advantages; it is not widely spread as expected within the last decade. The HCB is manufactured of self-consolidating concrete (SCC), which is poured in the shape of a traditional arch and tied at its ends by high-strength tendons. A durable FRP composite hull encapsulates the SCC arch and the high-strength tying tendons in order to create a structural beam element for bridge applications. The HCB's design aims to provide pure compressive stresses to the concrete and pure tensile stresses to the steel. The current study performs a deep numerical investigation of the FRP hull instead of other components comprehensively studied. Numerical validation is performed for the deflection results on the experimentally tested Knickerbocker HCB Bridge, the deformations are validated at four stages of HCB manufacturing and testing. Further, the FRP hull strength ratios are quantified for the worst value of four failure criteria. The results showed an excess use of FRP material, where more than 90% of FRP areas have strength ratios of 5 to 50. The FRP hull thickness is minimized using Genetic Algorithm optimization under the worst case of loading. The results achieved more than 60% decrease in FRP weight, that led to only 20% cost difference between traditional precast concrete and HCB girders. It is finally concluded that the overdesign of FRP hull contributed to the high cost of HCB usage consequently inefficient market spread.