Data-Driven Multi-Objective Design of Mass Concrete: Balancing Strength, Thermal Control, and Durability

Mass concrete design presents a significant challenge due to the inherent conflicts among key performance metrics: high compressive strength, low heat of hydration, and low water absorption (a key durability indicator). Traditional trial-and-error methods are inefficient and fail to systematically navigate these complex trade-offs. To address this, this study proposes a data-driven multi-objective optimization framework for mass concrete mix design. A comprehensive experimental dataset of 64 mixtures was established by varying the water-to-binder ratio (0.40–0.55), fly ash content (0–120 kg/m3), and slag content (0–120 kg/m3), with cement content fixed at 400 kg/m3. Kriging surrogate models were developed to accurately map the nonlinear relationships between these design variables and the three performance responses. These models were then integrated with the NSGA-II algorithm to generate a Pareto-optimal front of solutions. The framework’s predictive accuracy and generalization capability were rigorously validated through out-of-sample experiments, demonstrating prediction errors consistently below 10%. The results provide a quantified map of feasible engineering compromises, enabling engineers to select tailored mixtures for specific project priorities, such as low-heat mixes for dams or high-strength mixes for foundations.