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Cost optimisation of lattice-reinforced joist slabs using
genetic algorithmsV. C. de Castilho and M. C. V. de Lima
Genetic algorithms (GA), a search method inspired by Darwin’s theory of evolution, offer an optimisation tool has
been used very successfully to solve a variety of engineering problems. The search process it implements starts with
a set of one or more chromosomes (initial population) and, by applying selection and reproduction operators,
iteratively ‘evolves’ the population into hopefully better ones, until a stopping criteria is reached. This article
investigates lattice-reinforced joist slab cost optimisation problems using a GA with continuous variables.
The problem considered concerns one-way slabs, continuous over two spans, which only the in-situ concrete
characteristics and joist spacing are varied. The design variables are: concrete layer thickness, concrete layer
strength, reinforcement, distance between joists and degree of redistribution of the continuous slabs’ negative
moments. The search for a solution includes an investigation into the use of discrete variables for data
representation. To obtain results that allow for a comparative empirical analysis, these problems are also evaluated
by a conventional optimisation method. The results indicate that the GA method is a viable optimisation tool for
solving lattice-reinforced joist slab cost minimisation problems.
Vanessa Cristina deCastilhoUniversidade Federal deUberla ˆ ndia, Brazil
Maria Cristina Vidigalde Lima
Universidade Federal deUberla ˆ ndia, Brazil
Notation
h degree of redistribution
M ap negative bending moment after the
redistribution
M el negative bending moment for
elastic-linear materialf ( x ) cost function, in R$/m2
x 1 cast-in-place concrete, in m
x 2 compressive strength of the con-
crete, in MPa
x 3 distance between joists axes, in m
x 4 degree of redistribution, in %
Introduction
Researchers in the field of structural engineer-
ing have always attempted to devise optimised
design solutions. Indeed, few topics have
received more attention in structural analyses
than that of optimisation. In the area of
precast concrete structures, the optimisation
of elements is of major interest due to the
way these elements are produced. In Brazil,
one of the most common applications of
precast concrete elements is in buildings
slabs. These slabs usually consist of lattice-
reinforced joists, prestressed concrete joists,TT panels and hollow core panels.
In precast concrete elements, part of the
problem is the transitory stages of production,
transportation and assembly, which may
impose more unfavourable loads on these
elements than on cast-in-place structures.
These stages consist of:1
(a) production – execution of precast
concrete elements;
(b) transportation – moving from the
production to the building site;
(c ) assembly – placement of the elements in
their permanent position and execution
of the connections.
A robust solution to the problem of cost
minimisation of precast concrete structures
requires that all these stages be taken into
account.
This article analyses the cost optimization of
lattice-reinforced joist slabs based on genetic
algorithms (GAs).2,3 The problem variables are
the height and strength of the concrete, the
reinforcement, the distance between joists
and the coefficient of redistribution of the
negative moments of continuous slabs. Based
on these factors, the influence of the continu-
ous reinforcement is evaluated in the struc-
ture’s final cost.4,5 The variables are defined
initially as continuous and later as discrete,
since it is much easier to associate a discrete
set of values to the variables values because
they are more easily applied. To investigate
the potential of the GA, the same problemswere addressed using a conventional method,
the Excel Solver, which uses the nonlinear
optimisation code Generalized Reduced
Gradient (GRG2).
Genetic algorithm
The genetic algorithm (GA) is an optimisation
and search method based on the concepts of
genetics, i.e. the evolutionary mechanisms of
populations of live beings. GAs were inspired
on the principle of natural selection and
survival of the fittest established in 1859 by
Charles Darwin in his book The Origin of the
Species. According to Darwin’s theory, in any
given population, the individuals possessing
‘good’ genetic characteristics have better
chances for survival and reproduction than
the less ‘fit’ individuals, who tend to disappear
over time.
The GA simulates biological evolution by
means of a multidirectional search within the
space of potential solutions for the problem.
This algorithm maintains a constant number
of potential solutions (population), modifying
the population in each successive generation
SC5150 Techset Composition Ltd, Salisbury, U.K. 2/1/2007
1464–4177 # 2007 Thomas Telford and fib
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so that ‘good’ solutions can ‘reproduce’ and
pass on to the next generation, while ‘bad’solutions are discarded. GA generally uses
probabilistic transition rules to select some
solutions for reproduction and others to be
discarded. The basic principles of GA basic
were established in Holland6 and are men-
tioned in many bibliographical references.7–11
Each individual in a population (called a
‘chromosome’) usually corresponds to a point
in the search space and represents a possible
solution to the problem – this solution is also
called a hypothesis. The GA can explore the
space of possible solutions to seek the ‘best’one by applying its reproduction mechanism
on the individuals of the current population.
Instead of starting from a single point (or
potential solution) in the search space, a GA
is initialised with a population of potential sol-
utions. These potentials solutions are normally
generated randomly and represent dispersed
points in the search space.
A typical GA uses three operators –
selection, crossover and mutation – to guide
the population (through several generations)
toward a convergence at the global optimal
point. After the selection, crossover and
mutation operators have been applied, a new
population is formed. The process is repeated
until a given number of generations have
been created or another stop criterion is
reached.
These characteristics, organised into a pro-
cedure, can be rewritten as the pseudo-code
shown in Figure 1.
This optimisation tool is widely employed in
the search for solutions to innumerable pro-
blems in the field of engineering.12–17
Generalised reduced gradient
(GRG2)
The GRG2 is a nonlinear optimisation program
used by the Microsoft Excel Solver to solve
minimisation and maximisation problems.18
Basically, GRG2 uses an implementation of the
generalized reduced gradient algorithm (GRG).
To generalise the GRG algorithm, the func-
tions gradient is used, thus ensuring that,
regardless of the expression, a linear relation
among the variables is always obtained.
A typical optimisation problem with restric-
tions addressed via nonlinear programmingcan be equated as shown in Figure 2. In the
presence of inequations, the equations are
transformed using fictitious variables.
The solution to the optimisation problem is
found starting from this typical algorithm and
applying the characteristics of the GRG itself. In
addition to all these characteristics for solving
optimisation problems, unlike the GA, an initial
solution must also be supplied, whether it is
feasible or not.
Ribbed slabs with lattice-reinforced joists
Lattice-reinforced joist slabs can be treated as
monolithic structures because they are joined to
cast-in-place concrete. The behaviour of these
slabs is similar to that of conventionally designed
slabs, and these precast concrete elements playa
rational role, representing low-cost and fast con-
struction (EF-9619 and NBR 611820).
Lattice-reinforced joists are structures com-
posed of steel bars joined together by electrofu-
sion welding at various points to form a space
lattice. In the transitory phases, the diagonals
of these lattices confer rigidity on the set, as
well as excellent transport conditions and hand-
ling, and connections between the cast-in-place
concrete and the precast concrete base. More-
over, the lattices can be used as transversal
reinforcements to offset shear stresses.21–23
The concrete base is moulded in metal
moulds to ensure the quality of the concrete,which is applied in 2– 3 cm thickness, using
concrete with small rich aggregates in a aggre-
gate cement paste to avoid the vibration
operation (Figure 3).
Lattice-reinforced joists are usually pro-
duced in lengths varying from 80– 300 mm,
with possible one-centimetre variations. Each
type of joist is identified by a set of symbols,
as illustrated in the example below,24 where
TR-08634: TR characterises the lattice-
reinforced joist; 08 indicates the 8 cm high
lattice reinforcement; 6 indicates the f 6 mmgauge of the lattice’s upper bar; 3 indicates
the f 3 . 4 mm gauge of the diagonals; and
4 indicates the f 4 . 2 mm gauge of the lower
bars.
Lattice-reinforced joists can be produced by
order to include additional reinforcements
introduced in the concrete base without
complicating the production process.
El Debs1 points out that the use of this type
of lattice-reinforced joist favours the appli-
cation of bi-directional reinforcement slabs.
The Brazilian Civil Construction Committee
is currently studying the elaboration of the
Code for Prefabricated Slabs. Therefore, the
calculations normally used by design engineers
to dimension and check lattice-reinforced joist
slabs are those published by manufacturers of
precast elements, according to Diniz,25 Lima26
and Pereira.27
S (t ) – population of chromosomes in generation
t .
initialize S (t )
evaluate S (t )
while (not termination-condition)
begin
select S (t ) from S (t – 1)
crossover S (t )
mutation S (t )evaluatedS (t )
end
4 Figure 1 Typical genetic algorithm
minimize f (x )
Such that:
g i (X ) = 0, i = 1, neq
L j < X j < U j, j = 1, n
where L j and U j are the lower and upper
limits from x j.
4 Figure 2 Typical optimization algorithm
diagonals
concrete base
lower bars
additionalreinforcement
upper bar
h
4 Figure 3 Lattice-reinforced joists4
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The continuous reinforcement of the
lattice-reinforced joist was determined using
as the variable the degree of the bending
moment’s redistribution, taking care not toexceed the slab’s bearing capacity.28
The degree of redistributionh , expressed as
a percentage (Figure 4), is given by
h ¼ 1 M ap
M el
100(%)
where M ap is the negative bending moment
after the redistribution and M el is the negative
bending moment for elastic-linear material.
Solution of the cost optimizationproblem of lattice-reinforced
joists slabs
Costs and input for lattice-reinforced loists
The definition of the cost minimisation function
for the precast concrete elements studied here
was based on the costs of fabrication, external
transport and application. Listed below are the
partial values of the inputs in each stage. Note
that these values correspond to an initial analy-
sis of the problems evaluated in this work.
All prices are given in Brazilian Real (R$). The
conversion rate is 1.00USD ¼ 2.14BRL and
1.00EUR¼ 2.79BRL (at 16 May 2006). The
costs considered here are the same as those
adopted by Castilho:29
(a) Fabrication costs. The costs involved in the
production of precast concrete elements
correspond to the cost of raw material
(concrete, reinforcements, infill blocks),
factory activities (the cost of this phase
corresponds to the activities that take
place after moulding but before delivery
of the product), and administrative costs
(the overall costs involved in administrative
tasks and the salaries of the people
involved in the job). A breakdown of
these costs is given in Table 1.
(b) External transport cost . This is the cost of
transporting the joist from the factory to
the construction site, comprising labour,
trucks, fuel, insurance and maintenance
costs. For the purposes of this study, we
considered a construction site located
100 km from the factory.
External transport costs (R$=m3) ¼ 52
(c ) Assembly costs. The costs involved in the
assembly refer to the assembly of the
joist, the cast-in-place concrete, the comp-
lementary reinforcement and administra-
tive costs, as indicated in Table 2.
Definition of the problem
The solution for the problem of lattice-
reinforced joist slab cost optimization was
investigated here using genetic algorithms
(GAs). In addition to the traditional variables
of cast-in-place concrete strength, concrete
layer height and distance between joists, the
degree of redistribution variable was also ana-
lysed. The analysis comprised three lattice
reinforcement cases: the TR-08634 discussed
by Magalha ˜ es,4 and the TR-12645 and TR-
16645 available used in Brazilian market, all
with the same loading conditions.
The lattice-reinforced joist was optimised
under the same loading conditions adopted
by Magalha ˜ es:4
(a) Distributed uniformly along the element,
the loads were based on the concrete’s
dead weight (g c ¼ 25 kN/m3), expanded
polystyrene (EPS) infill blocks
(g e ¼ 0.12 kN/m3), a permanent load of
0.5 kN/m2 and a live load of 2.0 kN/m2.
(b) The slabs were dimensioned considering a
concrete base compressive strength of
20 MPa and a CA 60 reinforcement (yield
strength equal to 552 MPa).
(c ) The resistance factor used for concrete is
1.4 and 1.15 for steel. The load factor
used in the analysis is 1.4.
Figures 5 and 6 depict, respectively, the
static scheme and the slab section. The slab’s
uniform
distributedload
M apM el
4 Figure 4 Difference between M el and
M ap
Table 1 Fabrication costs
Material Labour Equipment
Raw material
Concrete: R$/m3 123.75 4.40 4.00
Reinforcement: R$/kg 1.80 0.25 –
Infill blocks: R$/m3 2.00 2.00 1.20
Factory activity: R$/m3 – 4.40 1.67
Administration: R$/m3 10%of theoverall costs involved in raw material, factory activity
Table 2 Assembly costs
Material Labour Equipment
Erection: R$/m3 – – 10.4
Cast-in-place concrete: R$/m3 (24.75 . f ck,capaþ 74.25) 110.75 –
Reinforcement: R$/kg 8.18 – –
Administration: R$/m3 20% of the overall costs involved in the assembly,
cast-in-place concrete and complementary reinforcement
4 m4 m
4 Figure 5 Static outline (span length 8 m)
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final section was completed with EPS infill
blocks and a layer of concrete.
The cost function was represented by
four variables: x 1 representing the height of
the cast-in-place concrete; x 2 representing
the concrete’s compressive strength; x 3
representing the distance between joists;
and x 4 representing the degree of
redistribution.
Three joists with heights (H e) of 8 cm,
12 cm and 16 cm (TR-08634, TR-12645 and
TR-16645) were analysed to find a solution
for the optimization problems of lattice-
reinforced joists loaded as mentioned earlier.
The height of the infill blocks is a function of
the slab’s total span:
(a) for a total span of 8 m (4 m–4 m):
H EPS¼ 8 cm; and
(b) for a total span of 12 m (6 m–6 m):
H EPS¼ 12 cm.
The process of designing the slab with
lattice-reinforced joists was the same as that
described by Magalha ˜ es.4 The design criteria
were based on the joist’s service limit state
and ultimate limit state.
Total cost function
Thevarious costs were added up to findthe func-
tion that represents the joist’s total production
cost, considering the stages of execution, trans-
portation and application. Further details regard-
ing the final expression of the function (equation
(1)) are described by Castilho.29
f ( x )¼1 115
x 3þ
(0 00122þ0 127 x 1 x 3
0 0127 x 1 þ0 0158 x 3
0 00395 x 3(100 x 4)0 01)2
(0 219þ 25 x 3 x 1
2 50 x 1 þ2 50 x 3)
( x 1 þ0 065)100
264
375
þ
(12 50 x 1 x 3 þ 0 000624
1 248 x 1)
x 3
þ120 (2 475 x 2 þ74:25)
12 50 x 1 x 3 þ0 000624
1 248 x 1 x 3
0
BB@
1
CCA
þ
34 3 x 1 þ14 57 x 2 x 3
(88 8 x 1 þ5 457)
(22 4 x 1 þ1 456)
((100 x 4)0 01=
4633 x 1 þ284 713)
x 1 x 3 þ0 000050 1 x 1(1)
where x 1 is cast-in-place concrete, in m; x 2 is com-
pressivestrengthof theconcrete,in Mpa; x 3 isdis-
tance between joists axes, in m; and x 4 is degree
of redistribution, in %.
Note that, after several tests, this function
was found to incorporate all the problem vari-
ables, offering the best representation of the
lattice-reinforced joist cost minimisation
Table 3 Inequalities for continuous and discrete variables
Continuous
variables
Discrete
variables
0.040 x 1 0.100: m x 1 ¼ f0.040, 0.050, 0.060, 0.070, 0.080, 0.090, 0.100g
15 x 2 30: MPa x 2 ¼ f15, 16, 17, 18, 19, . . . , 30g
0.300 x 3 0.600: m x 3 ¼ f0.300, 0.310, 0.320, 0.330, 0.340, . . . , 0.600g
0 x 4 40: % x 4 ¼ f0, 1, 2, 3, 4, 5, 6, 7, . . . , 40g
Table 4 Values of variables, reinforced areas and cost function for two spans2
TR-08634
TR08634
Span – 8 m Span – 12 m
GA GA Excel
Solver
GA GA Excel
Solver(cont_var) (disc_var) (cont_var) (disc_var)
x 1: m 0.040 0.040 0.040 0.094 0.100 0.085
x 2: Mpa 19.3 20.0 19.0 23.0 21.0 21.8 x 3: m 0.598 0.600 0.600 0.373 0.370 0.378
x 4: % 40 40 40 22 38 40
Cost function: R$/m2 19.96 20.58 20.34 39.55 38.84 35.56
Negative reinforcement:
1024 m2
1.90 1.97 1.96 2.76 2.07 2.12
Additional reinforcement/ joists: 1024 m2
1.19 1.19 1.19 1.20 1.23 1.56
EPS EPS EPS
10 10
H EPSx 1
EPS3
2 5
1·5
13
3
H e
additionalreinforcement
(a) slab cross-section (b) joist section (H e = joist length)
4 Figure 6 Slab cross-section and joist section (in cm)
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problem. These results are part of an initial
study of the negative moments in continuous
slabs with lattice-reinforced joists.
Therefore, the slab cost optimisation
problem boils down to the minimisation
problem f ( x ) ¼ ( x 1, x 2, x 3, x 4), which is subject
to service limit state and ultimate limit state
restrictions. In addition to these restrictions,
the continuous and discrete variables should
satisfy the inequalities presented in Table 3.
Description of the experimentsand analysis of the results
In this section we investigate the search for the
solution to the cost optimisation problem via
GA, based on the following characteristics:
elitism (1 individual), a population of 200
individuals, representation by real numbers,
uniform crossover, competition selection
strategy, and stop criterion delimited in 3000
generations. Since the GA is highly sensitive
to the initial population, the data describing
the results of each experiment represent the
average values obtained using five randomly
selected initial populations (average of five
runs).
Tables 4, 5 and 6 present the values
obtained for each variable and for the cost
function, using GA through continuous
(cont_var) and discrete (disc_var) variables.
The analysis involved TR-08634, TR-12645
and TR-16645 lattice-reinforced joists
with heights (H e) of 8 cm, 12 cm, and 16 cm,respectively, for two slab spans: 8 m
(4 m–4 m) and 12 m (6 m–6 m). For purposes
of reference, these tables also list the values of
the variables for the conventional optimization
method (Excel Solver), and the values evaluated
of the final areas of the negative (at middle
support) and additional reinforcement (one
joist) for each case. The reinforcement areas
(negative and additional) are not variables of
the optimisation method. Transverse reinforce-
ment is not required.
Tables 4, 5 and 6 indicate that, for largerspans of the same joist, there is:
(a) an increase in the height of the concrete
layer (in the case of TR-08634), which
was expected, since this increase leads to
an increase of the compression flange,
thereby enhancing the slab’s strength;
(b) an increase in the concrete layer strength.
Thus, increasing the span requires increas-
ing the slab’s strength, which is also
achieved by increasing the strength of
the cast-in-place concrete;
(c ) a reduction in the distance between joists,
in the case of the TR-08634 joist, which
was also expected, although there was
no alteration in the distance between the
other joists. The increased height of the
compression flange resulted in a shorter
distance between joists and, hence, a
reduction in the area of concrete, which
was reflected in a reduction of the cost
of the cast-in-place concrete;
(d ) an increase in the negative and additional
reinforcements, as expected.
A further analysis of the results shown in
the above tables indicates that, when the
height of the lattice is increased, the results
for the same span are inverted. As can be seen:
(a) in the case of the TR-08634 and TR-12645
joists with a 12 m span, the height of the
concrete layer decreased, and the distance
between joists increased. Conversely, as
the height of the compression flange
increased, the distance between joists
decreased to obtain the lowest cost for
concrete;
Table 5 Values of variables, reinforcedareas and cost function for twospans – TR-12645
TR-12645
Span – 8 m Span – 12 m
GA GA Excel
Solver
GA GA Excel
Solver(cont_var) (disc_var) (cont_var) (disc_var)
x 1: m 0.040 0.040 0.040 0.040 0.040 0.040
x 2: Mpa 18.2 19.0 18.2 19.5 20.0 20.0 x 3: m 0.599 0.600 0.600 0.597 0.580 0.600
x 4: % 40 40 40 40 38 31
Cost function: R$/m2 21.82 22.06 21.48 23.60 24.60 22.85
Negative reinforcement:
1024
m2
2.47 2.59 2.48 2.64 2.72 3.13
Additional reinforcement/ joists: 1024 m2
0.72 0.86 0.86 1.86 1.84 1.81
Table 6 Values of variables, reinforced areas and cost function for two spans2TR-16645
TR-16645
Span – 8 m Span – 12 m
GA GA Excel
Solver
GA GA Excel
Solver(cont_var) (disc_var) (cont_var) (disc_var)
x 1: m 0.040 0.040 0.040 0.040 0.040 0.040
x 2: MPa 16.5 17.0 17.0 18.5 19.0 18.9
x 3: m 0.599 0.600 0.600 0.599 0.600 0.600
x 4: % 40 40 40 40 40 40
Cost function: R$/m2 22.66 22.08 22.08 25.19 25.47 25.32
Negative reinforcement:
1024 m2
2.86 2.95 2.95 3.21 3.30 3.28
Additional reinforcement/ joist: 1024 m2
0.68 0.68 0.68 1.47 1.47 1.47
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(b) a reduction in the strength of the concrete
layer since, under the same load situation,
a lower slab strength was found to be
necessary to offset the loads.
Figures 7, 8 and 9 illustrate the behaviour
of the cost function for each generation,
using the GA (cont_var), for the three cases
listed in the tables. Note that the curves
depict the same tendency: up to the generation
of 500 individuals, the values of the cost func-
tion remained practically unchanged.
The results indicate that most of the
values obtained both with the GA, in the
case of continuous variables, and with the
conventional optimization method were
practically the same. It is worth noting
that the values obtained by the GA with
discrete variables were compatible with
those of the Excel Solver, leading us to con-
clude that the GA was effective in finding
the solution for the lattice-reinforced joist
cost optimisation problems.
Most conventional optimisation methods do
not work with discrete variables, which is a sig-nificant disadvantage. Another disadvantage
involved the initial points of the design vari-
ables. In the conventional method, the initial
values of the variables must be provided for
the initial processing. In our analysis of these
problems, the initial values corresponded to
those obtained via the GA (continuous
variables). Different initial values were
adopted to evaluate the sensitivity of the
Excel Solver optimisation method. In general,
the results (GA and Excel Solver) converged
to an optimum. In some cases, the algorithmdid not converge or showed no significant
improvement at all using GA with discrete
variables.
Conclusions
This work investigated the use of GAs to find
solutions for the cost optimisation of lattice-
reinforced joists. The problems involved slabs
with lattice-reinforced joists for TR-08634, TR-
12645 and TR-16645 lattices with span
lengths of 8 m and 12 m. In addition, an
analysis was made of the design variables,
some continuous and others discrete. For
purposes of comparison, the same problems
were evaluated using a conventional method
(Excel Solver).
The results of the cost function and the vari-
ables, in the case of TR-08634, indicate that
there was an increase in the height of the con-
crete layer, leading to an increase of the com-
pression flange and an increment in the slab’s
strength.
The longer span led to increased strength in
the concrete layer. This, in turn, led to the need
for increasing strength in the slab, which was
also obtained by increasing the strength of
the cast-in-place concrete. Moreover, the dis-
tance between these same joists decreased.
Increasing the height of the compression
flange led to reduction in the distance
between joists and, hence, a smaller area of
concrete, resulting in a reduction of the cost
of cast-in-place concrete.
The other lattices showed no change in
the distance between joists. All the lattices
analysed showed an increase in the negative
and additional reinforcements.
TR-08634 – cost x generation
15
20
25
30
35
40
45
generation
c o s t : R $ / m 2
span = 8 m
span = 12 m
0 500 1000 1500 2000 2500 3000 3500
4 Figure 7 Average cost function values for TR-08634
TR-12645 – cost x generation
20
21
22
23
24
25
26
generation
c o s t : R $ / m 2
span = 8m
span = 12m
0 500 1000 1500 2000 2500 3000 3500
4 Figure 8 Average cost function values for TR-12645
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Based on these analyses, we found that
most of the values of the variables for the GA
(discrete variables) and for the Excel Solvertended toward the same results. Therefore,
we concluded that the GA optimisation tool
efficiently solved the cost optimization
problems of the lattice-reinforced joists ana-
lysed here.
References
1. El Debs, M. K. Concreto pre -moldado: funda-
mentos e aplicaco es. (In English: Precast con-
crete: fundamentals and applications). Projeto
REENGE, EESC-USP, Sa ˜ o Carlos, 2000.
2. Castilho, V. C., Nicoletti, M. and El Debs, M. K.
An investigation of the use of three selection-
based genetic algorithm families when minimiz-
ing the production cost of hollow core slabs.
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TR-16645 – cost x generation
20
21
22
23
24
25
26
27
28
29
30
generation
c o s t : R $ / m 2
span
=
8
mspan = 12 m
0 500 1000 1500 2000 2500 3000 3500
4 Figure 9 Average cost function values for TR-16645
Structural Concrete 2007 8 No 1
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