Dual-Layer Sustainable Optimization Framework: An Application to Building Structure Floor Design

The construction industry is one of the primary global contributors to carbon emissions, with both construction materials and operational energy recognized as critical factors in achieving net-zero goals. Given that structural systems are embodied carbon-intensive, significant early-stage carbon reductions are possible. This paper introduces the dual-layer sustainable optimization framework (DLSOF), a methodology that integrates system-level substitution with span-level optimization and a single life-cycle assessment (LCA) approach focused on embodied carbon (EC) that is applicable to various construction types and climate regions. To validate DLSOF, two representative models of reinforced concrete buildings were selected for analysis: one focused on alternate structural systems and the other on span optimization for a standard slab configuration. The results indicate that, in most cases, span optimization achieves a reduction in embodied carbon of 33%, whilst system-level substitution, in most cases, achieves a reduction of approximately 30%. The dual-layer approach, in comparison to conventional baseline designs, achieves approximately a 52% reduction in embodied carbon. Uncertainty analysis indicates variability in design and data inputs, but the overall trend of embodied carbon reduction remains consistent. The results highlight the critical nature of the early structural design stage. For engineers, the DLSOF provides a practical design pathway, and it offers flexibility to accommodate diverse sustainability goals across varying geographical contexts. This study establishes a replicable and transferable model for low-carbon structural design by systematically integrating design optimization with embodied carbon assessment.