Abstract To mitigate the impact of subgrade settlement on pavement in permafrost regions, an innovative prefabricated pavement structure system composed of longitudinal and transverse beams combined with concrete slabs was proposed and designed. The mechanical performance indicators under the most unfavorable conditions were evaluated using ANSYS finite element software. The direct shooting method was employed to systematically optimize the dimensions of the prefabricated pavement structure components. The results indicate that the prefabricated pavement structure exhibits excellent deformation resistance during subgrade settlement. The direct shooting method optimized the prefabricated pavement structure, ensuring structural safety while reducing weight and minimizing construction costs. Furthermore, a correlation analysis was conducted on the dimensions of the structural components affecting maximum deformation, maximum equivalent stress, and overall structural volume. The analysis identified the significant influence of the upper flange plate of the steel beam and the bottom steel plate on the overall mechanical performance and steel consumption of the pavement structure.
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