Optimal Plastic Design of Reinforced Concrete Structures: A State-of-the-Art Review from Steel Plasticity to Modern RC Applications

Plastic design enables efficient structural systems by exploiting controlled inelastic deformation and force redistribution. While mature in steel structures due to stable ductility and well-defined yielding, its extension to reinforced concrete (RC) remains challenging because cracking, stiffness degradation, confinement dependency, and progressive damage govern deformation capacity and collapse mechanisms. This paper presents a state-of-the-art review of optimal plastic design methodologies for RC structures by tracing the evolution from classical plasticity theory to modern damage-informed, reliability-oriented, and sustainability-driven formulations. A systematic and structured literature review of more than 90 peer-reviewed journal articles (1990–2025) was conducted using Scopus, Web of Science, and ScienceDirect. The selected studies are classified by structural system type, plastic analysis approach, constitutive modeling strategy, and strengthening technique, including CFRP and hybrid fiber systems, optimization framework, and uncertainty treatment. The review highlights how nonlinear elasto-plastic and damage–plasticity models improve the prediction of plastic hinge development, redistribution, and failure-mode transitions, and how metaheuristic optimization, topology optimization, surrogate modeling, and machine learning are increasingly used to manage discrete design variables and computational cost. Reliability-based methods (e.g., FORM/SORM and simulation) are shown to be essential for quantifying deformation-capacity uncertainty and ensuring consistent collapse-prevention performance. A comparative assessment of nine plastic design methodologies is also provided, identifying their core assumptions, limitations, and domains of applicability within a structured evaluative framework. Remaining challenges include robust deformation-capacity prediction, reproducible calibration of damage models, and integration of life-cycle sustainability criteria within reliability-constrained plastic optimization. Future research directions are proposed toward multi-objective reliability-based design, durability-informed plastic modeling, and hybrid physics-informed AI-assisted workflows.