TOPS – Topology-optimised reinforced concrete slabs with digital formwork and reinforcement

Starting point / motivation

The cement industry is responsible for 8% of global CO₂ emissions, making the resource-efficient use of concrete a key lever for achieving climate goals. In addition to long-term strategies to decarbonise concrete production, there is immediate potential to reduce emissions by optimising the use of concrete in the construction industry. 

Floor slabs in particular, which account for up to 60% of the concrete volume of a building, offer significant savings potential. Traditionally, these are cast as solid slabs, resulting in inefficient use of material. In fact, only a fraction of the concrete is needed for the load-bearing capacity, while most of the material is used for construction reasons alone.

Contents and goals

TOPS investigates the potential of material-efficient ribbed slabs through the use of digital technologies and topology optimisation, with the aim of reducing the carbon footprint by up to 50% compared to conventional solid slabs. This reduction is achieved through an optimised structure that uses material only where it is structurally necessary, while saving concrete and steel in other areas. 

In addition, the production of such slabs will be largely digitised to enable economical and resource-efficient production. TOPS thus makes an important contribution to the decarbonisation of the construction sector and supports the achievement of several sustainability goals, in particular in the areas of resource-efficient construction (SDG 12.2), modern infrastructure (SDG 9.4) and increased productivity through technological innovation (SDG 8.2).

Methods

In the TOPS project, a digitally manufactured demonstrator will be used to provide functional verification of material-efficient, topology-optimised ribbed slabs. To this end, a file-to-factory workflow is being developed that combines digital design with automated production of formwork and reinforcement. 

The slab's load-bearing capacity and savings potential will be evaluated in load tests compared to conventional solutions. The aim of this work is to demonstrate that a sustainable reduction in material use in the construction industry is possible through digital processes and optimised structures.

Expected results

TOPS brings significant innovation to the construction industry. With topology optimisation, a new method for the production of concrete slabs is introduced. Material-efficient ribbed slabs have been developed in the past, but have failed due to the costly production process. 

Thanks to digital design and production with file-to-factory workflows, production can now be achieved efficiently and economically. In addition, the environmental footprint of the project will be minimised through the integration of sustainable, proven materials, while ensuring industrial applicability.

Project management

TU Wien – Institut für Tragkonstruktionen, Forschungsbereich Stahlbeton- und Massivbau

Project or cooperation partners

• DataB GmbH
• Mesh AG

Dr. Tobias Huber
Karlsplatz 13/E212-2
A-1040 Vienna

Tel.: +43 (1) 58801 21242
E-mail: tobi.huber@tuwien.ac.at
Web: www.tuwien.at/cee/tragkonstruktionen/beton