client/src/lib/foundationRecommender.ts

// BhoomiBandhan – Foundation Type Recommender
// Rule-based foundation selection based on soil properties and loading conditions

interface SoilProperties {
  type: 'clay' | 'sand' | 'loam' | 'silt' | 'gravel' | 'rock';
  bearing_capacity?: number; // kN/m²
  plasticity_index?: number;
  moisture_content?: number;
  density?: number; // kg/m³
}

interface LoadRequirement {
  total_load: number; // kN
  load_type: 'light' | 'medium' | 'heavy' | 'very_heavy';
  structure_type: 'residential' | 'commercial' | 'industrial' | 'bridge' | 'tower';
  safety_factor?: number;
}

interface FoundationRecommendation {
  foundation_type: 'shallow' | 'deep' | 'pile' | 'raft' | 'caisson' | 'mat';
  sub_type: string;
  depth_recommendation: string;
  width_recommendation: string;
  reinforcement_needed: boolean;
  estimated_cost_range: string;
  construction_considerations: string[];
  is_standards: string[];
  confidence: number;
  warnings: string[];
}

class FoundationRecommender {
  private soilBearingCapacity = new Map([
    ['clay', { soft: 50, medium: 150, hard: 300 }],
    ['sand', { loose: 100, medium: 200, dense: 400 }],
    ['loam', { soft: 75, medium: 175, hard: 350 }],
    ['silt', { soft: 40, medium: 120, hard: 250 }],
    ['gravel', { loose: 200, medium: 400, dense: 600 }],
    ['rock', { soft: 1000, medium: 3000, hard: 10000 }]
  ]);

  private loadCategories = new Map([
    ['light', { min: 0, max: 500 }], // kN
    ['medium', { min: 500, max: 2000 }],
    ['heavy', { min: 2000, max: 10000 }],
    ['very_heavy', { min: 10000, max: 100000 }]
  ]);

  recommendFoundation(soil: SoilProperties, load: LoadRequirement): FoundationRecommendation {
    try {
      // Input validation
      this.validateInputs(soil, load);

      // Determine soil bearing capacity
      const bearingCapacity = this.determineBearingCapacity(soil);
      
      // Calculate required foundation area
      const safetyFactor = load.safety_factor || 2.5;
      const requiredArea = (load.total_load * safetyFactor) / bearingCapacity;

      // Apply foundation selection logic
      const recommendation = this.selectFoundationType(soil, load, bearingCapacity, requiredArea);
      
      // Add IS code references and construction considerations
      recommendation.is_standards = this.getRelevantISCodes(recommendation.foundation_type);
      recommendation.construction_considerations = this.getConstructionConsiderations(soil, recommendation);

      return recommendation;

    } catch (error) {
      throw new Error(`Foundation recommendation failed: ${error instanceof Error ? error.message : 'Unknown error'}`);
    }
  }

  private validateInputs(soil: SoilProperties, load: LoadRequirement): void {
    if (!soil.type || !['clay', 'sand', 'loam', 'silt', 'gravel', 'rock'].includes(soil.type)) {
      throw new Error('Invalid soil type. Must be one of: clay, sand, loam, silt, gravel, rock');
    }

    if (!load.total_load || load.total_load <= 0) {
      throw new Error('Total load must be a positive number');
    }

    if (!load.load_type || !['light', 'medium', 'heavy', 'very_heavy'].includes(load.load_type)) {
      throw new Error('Invalid load type. Must be one of: light, medium, heavy, very_heavy');
    }

    if (!load.structure_type || !['residential', 'commercial', 'industrial', 'bridge', 'tower'].includes(load.structure_type)) {
      throw new Error('Invalid structure type');
    }

    if (load.safety_factor && (load.safety_factor < 1.5 || load.safety_factor > 5.0)) {
      throw new Error('Safety factor must be between 1.5 and 5.0');
    }
  }

  private determineBearingCapacity(soil: SoilProperties): number {
    if (soil.bearing_capacity && soil.bearing_capacity > 0) {
      return soil.bearing_capacity;
    }

    const capacityRange = this.soilBearingCapacity.get(soil.type);
    if (!capacityRange) {
      throw new Error(`Unknown soil type: ${soil.type}`);
    }

    // Determine soil consistency based on properties
    let consistency: 'soft' | 'medium' | 'hard' = 'medium';
    
    if (soil.type === 'clay') {
      if (soil.plasticity_index) {
        if (soil.plasticity_index < 15) consistency = 'soft';
        else if (soil.plasticity_index > 30) consistency = 'hard';
      }
    } else if (soil.type === 'sand' || soil.type === 'gravel') {
      if (soil.density) {
        if (soil.density < 1600) consistency = 'soft';
        else if (soil.density > 1800) consistency = 'hard';
      }
    }

    return capacityRange[consistency];
  }

  private selectFoundationType(
    soil: SoilProperties, 
    load: LoadRequirement, 
    bearingCapacity: number, 
    requiredArea: number
  ): FoundationRecommendation {
    
    const warnings: string[] = [];
    let confidence = 85;

    // Foundation selection logic based on multiple criteria
    if (load.total_load < 500 && bearingCapacity > 150) {
      // Light loads on good soil - Shallow foundations
      return this.getShallowFoundationRecommendation(soil, load, requiredArea, warnings, confidence);
    }
    
    if (requiredArea > 100 || load.structure_type === 'industrial') {
      // Large area required or industrial structure - Consider raft/mat
      return this.getRaftFoundationRecommendation(soil, load, requiredArea, warnings, confidence);
    }
    
    if (bearingCapacity < 100 || soil.type === 'clay' && (soil.plasticity_index || 0) > 25) {
      // Poor soil conditions - Deep foundations
      return this.getDeepFoundationRecommendation(soil, load, warnings, confidence);
    }
    
    if (load.total_load > 10000 || load.structure_type === 'bridge' || load.structure_type === 'tower') {
      // Heavy loads or special structures - Pile foundations
      return this.getPileFoundationRecommendation(soil, load, warnings, confidence);
    }

    // Default to shallow with detailed analysis
    return this.getShallowFoundationRecommendation(soil, load, requiredArea, warnings, confidence);
  }

  private getShallowFoundationRecommendation(
    soil: SoilProperties, 
    load: LoadRequirement, 
    requiredArea: number, 
    warnings: string[], 
    confidence: number
  ): FoundationRecommendation {
    
    const width = Math.sqrt(requiredArea);
    let subType = 'isolated_footing';
    
    if (width > 3) {
      subType = 'combined_footing';
      warnings.push('Large footing size may require combined or continuous footings');
    }
    
    if (soil.type === 'clay' && (soil.moisture_content || 0) > 25) {
      warnings.push('High moisture content in clay may cause settlement issues');
      confidence -= 10;
    }

    return {
      foundation_type: 'shallow',
      sub_type: subType,
      depth_recommendation: `Minimum ${Math.max(1.0, width / 6).toFixed(1)}m depth, below frost line`,
      width_recommendation: `${width.toFixed(1)}m x ${width.toFixed(1)}m (Area: ${requiredArea.toFixed(1)}m²)`,
      reinforcement_needed: width > 1.5,
      estimated_cost_range: `₹${(requiredArea * 3000).toLocaleString()} - ₹${(requiredArea * 5000).toLocaleString()}`,
      construction_considerations: [],
      is_standards: [],
      confidence,
      warnings
    };
  }

  private getRaftFoundationRecommendation(
    soil: SoilProperties, 
    load: LoadRequirement, 
    requiredArea: number, 
    warnings: string[], 
    confidence: number
  ): FoundationRecommendation {
    
    warnings.push('Raft foundation recommended due to large load distribution requirement');
    
    if (soil.type === 'clay') {
      warnings.push('Monitor for differential settlement in clay soils');
      confidence -= 5;
    }

    return {
      foundation_type: 'raft',
      sub_type: 'reinforced_concrete_raft',
      depth_recommendation: `${Math.max(1.5, requiredArea / 50).toFixed(1)}m thick slab`,
      width_recommendation: `Full building footprint with ${requiredArea.toFixed(1)}m² effective area`,
      reinforcement_needed: true,
      estimated_cost_range: `₹${(requiredArea * 8000).toLocaleString()} - ₹${(requiredArea * 12000).toLocaleString()}`,
      construction_considerations: [],
      is_standards: [],
      confidence,
      warnings
    };
  }

  private getDeepFoundationRecommendation(
    soil: SoilProperties, 
    load: LoadRequirement, 
    warnings: string[], 
    confidence: number
  ): FoundationRecommendation {
    
    warnings.push('Deep foundation required due to poor surface soil conditions');
    
    const depth = soil.type === 'clay' ? 8 : 6;
    
    return {
      foundation_type: 'deep',
      sub_type: 'drilled_shaft',
      depth_recommendation: `${depth}m to ${depth + 4}m depth to reach competent soil`,
      width_recommendation: `${Math.sqrt(load.total_load / 500).toFixed(1)}m diameter shafts`,
      reinforcement_needed: true,
      estimated_cost_range: `₹${(load.total_load * 15).toLocaleString()} - ₹${(load.total_load * 25).toLocaleString()}`,
      construction_considerations: [],
      is_standards: [],
      confidence,
      warnings
    };
  }

  private getPileFoundationRecommendation(
    soil: SoilProperties, 
    load: LoadRequirement, 
    warnings: string[], 
    confidence: number
  ): FoundationRecommendation {
    
    const pileCapacity = soil.type === 'sand' ? 800 : soil.type === 'clay' ? 600 : 1000;
    const numberOfPiles = Math.ceil(load.total_load / pileCapacity);
    
    warnings.push(`${numberOfPiles} piles required for load distribution`);
    
    if (load.structure_type === 'bridge') {
      warnings.push('Consider seismic and lateral load requirements for bridge foundations');
    }

    return {
      foundation_type: 'pile',
      sub_type: 'driven_concrete_pile',
      depth_recommendation: `12m to 20m depth depending on soil profile`,
      width_recommendation: `${numberOfPiles} piles of 400mm diameter in ${Math.ceil(Math.sqrt(numberOfPiles))}x${Math.ceil(numberOfPiles/Math.ceil(Math.sqrt(numberOfPiles)))} grid`,
      reinforcement_needed: true,
      estimated_cost_range: `₹${(numberOfPiles * 50000).toLocaleString()} - ₹${(numberOfPiles * 80000).toLocaleString()}`,
      construction_considerations: [],
      is_standards: [],
      confidence,
      warnings
    };
  }

  private getRelevantISCodes(foundationType: string): string[] {
    const codes: string[] = ['IS 1904-1986 (Code of Practice for Design and Construction of Foundations)'];
    
    switch (foundationType) {
      case 'shallow':
        codes.push('IS 6403-1981 (Code of Practice for Determination of Bearing Capacity of Shallow Foundations)');
        break;
      case 'pile':
        codes.push('IS 2911-2010 (Code of Practice for Design and Construction of Pile Foundations)');
        break;
      case 'raft':
        codes.push('IS 456-2000 (Plain and Reinforced Concrete Code of Practice)');
        break;
      case 'deep':
        codes.push('IS 4968-1976 (Code of Practice for Subsurface Investigation for Foundations)');
        break;
    }
    
    codes.push('IS 1893-2016 (Criteria for Earthquake Resistant Design of Structures)');
    return codes;
  }

  private getConstructionConsiderations(soil: SoilProperties, recommendation: FoundationRecommendation): string[] {
    const considerations: string[] = [];
    
    if (soil.type === 'clay') {
      considerations.push('Protect excavation from water infiltration');
      considerations.push('Monitor for swelling/shrinkage during construction');
      considerations.push('Consider dewatering if groundwater is encountered');
    }
    
    if (soil.type === 'sand') {
      considerations.push('Maintain stable excavation slopes');
      considerations.push('Consider temporary shoring for deep excavations');
    }
    
    if (recommendation.foundation_type === 'pile') {
      considerations.push('Conduct pile load tests as per IS 2911');
      considerations.push('Monitor for pile driving vibrations affecting nearby structures');
    }
    
    considerations.push('Conduct soil investigation as per IS 1892');
    considerations.push('Ensure proper concrete quality control as per IS 456');
    considerations.push('Implement safety measures as per IS 14846');
    
    return considerations;
  }

  // Helper method to get foundation suitability matrix
  getFoundationSuitabilityMatrix(): Record<string, Record<string, string>> {
    return {
      'clay': {
        'light': 'Shallow footings with proper drainage',
        'medium': 'Raft or deep foundations depending on plasticity',
        'heavy': 'Pile foundations or deep caissons',
        'very_heavy': 'Large diameter piles or caisson groups'
      },
      'sand': {
        'light': 'Shallow strip or pad footings',
        'medium': 'Combined footings or shallow raft',
        'heavy': 'Driven piles or drilled shafts',
        'very_heavy': 'Large pile groups with pile caps'
      },
      'loam': {
        'light': 'Shallow footings with standard reinforcement',
        'medium': 'Reinforced footings or small raft',
        'heavy': 'Deep foundations or pile groups',
        'very_heavy': 'Engineered pile foundations'
      },
      'rock': {
        'light': 'Direct bearing on rock surface',
        'medium': 'Shallow foundations on rock',
        'heavy': 'Rock anchored foundations',
        'very_heavy': 'Rock socketed caissons'
      }
    };
  }

  // Export recommendation as detailed report
  generateDetailedReport(recommendation: FoundationRecommendation, soil: SoilProperties, load: LoadRequirement): string {
    const report = `
FOUNDATION DESIGN RECOMMENDATION REPORT
=====================================

PROJECT DETAILS:
- Structure Type: ${load.structure_type}
- Total Load: ${load.total_load} kN
- Load Category: ${load.load_type}
- Safety Factor: ${load.safety_factor || 2.5}

SOIL CONDITIONS:
- Soil Type: ${soil.type}
- Bearing Capacity: ${soil.bearing_capacity || 'Estimated'} kN/m²
- Plasticity Index: ${soil.plasticity_index || 'Not specified'}
- Moisture Content: ${soil.moisture_content || 'Not specified'}%

RECOMMENDED FOUNDATION:
- Type: ${recommendation.foundation_type}
- Sub-type: ${recommendation.sub_type}
- Depth: ${recommendation.depth_recommendation}
- Dimensions: ${recommendation.width_recommendation}
- Reinforcement Required: ${recommendation.reinforcement_needed ? 'Yes' : 'No'}
- Estimated Cost: ${recommendation.estimated_cost_range}

CONSTRUCTION CONSIDERATIONS:
${recommendation.construction_considerations.map(c => `- ${c}`).join('\n')}

APPLICABLE IS CODES:
${recommendation.is_standards.map(code => `- ${code}`).join('\n')}

WARNINGS AND NOTES:
${recommendation.warnings.map(w => `- ${w}`).join('\n')}

Confidence Level: ${recommendation.confidence}%

Generated by Prithvi Guardian AI - BhoomiBandhan Module
Report Date: ${new Date().toLocaleDateString('en-IN')}
`;
    return report;
  }
}

export const foundationRecommender = new FoundationRecommender();
export { SoilProperties, LoadRequirement, FoundationRecommendation };