TECH
Machine learning tool could speed up fire safety assessments for steel beams
The numerous advantages of steel in construction, such as strength-to-weight ratio, ease of construction, etc., have made steel structures widely used in various industries. However, when compared to concrete, in the case of fire incidence, steel beams can experience significant deformation, compromising their structural integrity and posing serious risks to life and property. For this reason, an efficient approach to measuring and evaluating the deformation of steel beams when subjected to fire is essential for accurately quantifying fire-induced damage, which will consequently facilitate efficient decision-making (process). Historical fire incidents around the world, such as the World Trade Center (2001) and the Grenfell Tower (2017) have underscored the vulnerability of steel structures to fire. According to a statistical report on fire accidents around the world, over seven million fire accidents took place all over the world causing about seventy thousand casualties. With the increase of structural fire knowledge, considerations for fire resistance are incorporated into standards.
These considerations are traditionally based on standard experiments conducted on individual structural members subjected to predetermined boundary conditions and structural loading. This practice, despite being accepted by engineering practitioners and academicians, has certain limitations. A typical example is the seven large-scale fire tests (BS 8414‐1) commissioned by the UK government following the Grenfell event to determine the combinations of insulation and aluminium composite material (ACM) cladding that could be safely used. According to the method, it is required that the test be stopped when flames are observed higher than the test.
Thus, this method cannot be used to examine all façade fire scenarios. The common practice is to perform these tests on an individual-member level, which, in addition to the inability to capture real fire scenarios and neglecting the mechanical influence of the other structural members, is also expensive and time-consuming. While BS 8414-1 cannot (economically) simulate the wide range of real-world fire propagation scenarios or predict structural behavior beyond visual flame spread, the proposed ML-based regression approach addresses this limitation by learning from comprehensive fire test data to predict continuous deformation patterns across diverse fire exposure conditions. Furthermore, empirical formulas derived from experimental results typically consider the temperature distribution along the beam's cross-section and use simplified assumptions to estimate the resulting deformations. However, these formulas often lack accuracy and fail to capture the complex behaviour of steel subjected to high temperatures.
They also assume uniform heating across the beam, which is not representative of real fire scenarios. As a result, empirical formulas may lead to significant deviations in predicting the actual fire-induced deformations. Hence, numerical simulation is considered a useful tool to investigate, understand, and analyse such fires, and, of particular use, specific phenomena can be isolated and evaluated more easily in a mathematical and cost-effective way. Several studies have shown the feasibility and usefulness of numerical simulation for high-rise building fires. The application of computational fluid dynamics and fire dynamics simulator for numerical simulations entails a deeper analysis of the fire propagation pattern in the World Trade Centre after the incident. In addition to employing standard fire curves, some researchers successfully adapt multiple fire models to simulate complicated fire scenarios in more accurately and effectively.
While these methods have provided valuable insights into the fire-induced deformation of steel beams, they have certain limitations. Some of the limitations include the complexity of developing a comprehensive model, which also requires advanced knowledge in mathematics as well as mechanics. They often rely on simplifying assumptions and may not accurately capture the intricate behaviour of steel under fire conditions. Additionally, traditional methods can be time-consuming, computationally expensive, and require significant expertise to implement.
Researchers at The University of Manchester, Shandong Jiaotong University and Harbin Engineering University have developed a machine learning framework, enabling rapid prediction of how protected steel beams respond during a fire, offering engineers a faster way to assess fire safety performance in industrial structures.
The study, published in the KSCE Journal of Civil Engineering, focuses on three-sided protected steel beams, a configuration commonly used in offshore and onshore oil and gas processing facilities. In these structures, the upper surface of the beam remains exposed, creating complex temperature patterns that can be difficult to model accurately.
Understanding how heat moves through these beams during a fire is an important part of structural fire engineering. However, temperature distribution is influenced by several interacting factors, including beam depth, insulation thickness and material conductivity, making conventional analytical equations challenging to apply across different scenarios.
To address this challenge, the researchers created an automated workflow that links computer modelling, simulation and data processing. The system combines Python, ABAQUS and MATLAB with machine learning techniques to automatically generate models, run simulations and train predictive algorithms.
The team generated a database containing 414 standard beam models and 63 welded beam models, covering beam depths ranging from 127 mm to 1500 mm and a variety of insulation configurations. These data were then used to train machine learning models capable of predicting beam temperatures during fire exposure.
“Current fire engineering assessments often rely on detailed numerical simulations, which require significant time and computing resources, while analytical equations are limited in accuracy by the number of parameters. Our framework demonstrates how machine learning can be combined with automated modelling techniques to deliver accurate temperature predictions much more efficiently. This could support the evaluation of fire protection systems across a wide range of steel beam configurations„...Dr Yang Li, Department of Civil Engineering and Management
The researchers found that the best-performing approach, based on gradient boosting, achieved a root mean squared error of just 1.34°C when compared with test data. More than 83% of prediction calculations were completed within 60 seconds, demonstrating the potential for rapid assessment of fire protection requirements.
The study also introduced a model generation agent incorporating a two-dimensional contact detection algorithm, enabling the automatic creation of beam heat transfer models. A dedicated data processing pipeline and batch-generation system were developed to support large-scale training while reducing memory requirements, allowing the work to be carried out using a single graphics processing unit.
According to the researchers, the approach could help engineers evaluate insulation strategies and fire protection requirements more efficiently, particularly in sectors where structural fire performance is a key design consideration. By reducing the need for repeated complex simulations, the framework has the potential to support faster decision-making during engineering design and assessment.
The research was conducted by Yang Li and Peijun Wang et al. The paper lists the Department of Civil Engineering and Management of The University of Manchester and Shandong University, as the authors' institutional affiliation.
The new artificial intelligence tool developed by researchers at the University of Manchester, in collaboration with Shandong Jiaotong University and Harbin Engineering University, promises to revolutionize and drastically accelerate fire safety assessments for protected steel beams. The model replaces lengthy, complex physical simulations with heat transfer predictions in record time.
The model's technical impact... Traditionally, engineers rely on expensive practical tests or Finite Element Analysis (FEA) simulations that require high computing power and hours of processing time. The machine learning-based approach overcomes these barriers with impressive results.
Remarkable speed: Over 83% of prediction calculations were completed in less than 60 seconds.
Surgical precision: The most efficient technique, based on gradient boosting, achieved a root mean square error (RMSE) of just 1.34°C compared to actual experimental data.
Accessible hardware: Thanks to a dedicated data processing and batch generation pipeline, memory requirements were drastically and efficiently reduced, allowing the entire large-scale training process to run on a single graphics processing unit (GPU).
Thermal model automation... In addition to predicting the failure temperatures of metal alloys, the study introduced an intelligent model-generating agent that incorporates a two-dimensional contact detection algorithm. This means the AI itself can automatically create heat transfer models for the beams, enabling engineers to rapidly test a wide range of thermal insulation thicknesses and passive fire protection strategies.
This technology optimizes decision-making during the early stages of civil engineering projects, ensuring structurally safer buildings without inflating costs through endless simulations.
