A Multi-Stage Framework Combining Experimental Testing, Numerical Calibration, and AI Surrogates for Composite Panel Characterization

Composite modular panels are increasingly used in modern buildings, yet their layered behavior makes mechanical characterization and modeling difficult. This study presents a novel hybrid framework that integrates analytical, numerical, and AI-driven approaches for the mechanical characterization of composite panels. The system combines a layered concrete configuration with embedded steel reinforcement, and its performance was evaluated through experimental testing, analytical formulation, finite element simulations, and artificial intelligence techniques. Full-scale bending and shear tests were conducted and results in terms of displacements were compared with in silico simulations. The equivalent elastic modulus and thickness were suggested via a closed-form analytical procedure and validated numerically, showing less than 3% deviation from experiments. These equivalent parameters were used to simulate the dynamic response of a two-storey prototype building under harmonic excitation, with simulated modal periods differing by less than 10% from experimental data. To generalize the method, a parametric dataset of 218 panel configurations was generated by varying material and geometric properties. Machine learning models including Artificial Neural Network, Random Forest, Gradient Boosting, and Extra Trees were trained on this dataset, achieving R2 > 0.98 for both targets. A graphical user interface was developed to integrate the trained models into an engineering tool for fast prediction of equivalent properties. The proposed methodology provides a unified and computationally efficient approach that combines physical accuracy with practical usability, enabling rapid design and optimization of composite panel structures.