The TOPS project is investigating material-efficient ribbed ceilings made of reinforced concrete that save up to 50% concrete compared to conventional flat ceilings through topology optimization. A “file-to-factory” process enables automated formwork and reinforcement production using digital technologies. The use of this construction method reduces CO₂ emissions and contributes to the decarbonization of the construction industry.

Starting Situation/Motivation

The cement industry is responsible for 8% of global CO₂ emissions, making the resource-efficient use of concrete a key lever in achieving climate goals. In addition to long-term strategies for decarbonizing concrete production, there is immediate potential for reduction through the optimized use of concrete in construction. In particular, floor slabs, which account for up to 60% of the concrete volume in a building, offer significant savings potential. Traditionally, these are cast in full cross-sections, leading to inefficient use of material. In fact, only a small fraction of the concrete is needed for structural strength, while most of the material is used for practical construction reasons.

Content and Objectives

TOPS explores the potential of material-efficient ribbed slabs through the use of digital technologies and topology optimization, aiming to reduce the CO₂ footprint by up to 50% compared to conventional flat slabs. This reduction is achieved through an optimized structure that uses material only where it is statically required, while concrete and steel are saved in other areas. Additionally, the production of such slabs should be largely digitized to enable cost-effective and resource-efficient manufacturing. TOPS thus makes an important contribution to decarbonizing the construction sector and supports the achievement of several sustainability goals, particularly in the areas of resource-efficient building (SDG 12.2), modern infrastructure (SDG 9.4), and productivity enhancement through technological innovation (SDG 8.2).

Methodological Approach

As part of the TOPS project, the structural performance of material-efficient, topology-optimized ribbed slabs will be demonstrated through a digitally fabricated demonstrator. To this end, a "File-to-Factory" process will be developed that connects digital planning with the automated production of formwork and reinforcement. The load-bearing capacity and potential savings of the slab will be evaluated through load tests in comparison to conventional solutions. This work aims to demonstrate that sustainable reductions in material usage in construction are possible through digital processes and optimized structures.

Expected Results

TOPS brings significant innovations to the construction sector. By applying topology optimization, a method that has not yet been used in practice for the production of concrete slabs will be introduced. Material-efficient ribbed slabs have been developed in the past, but they have not been widely adopted due to the complex manufacturing processes. Through digital planning and manufacturing within the "File-to-Factory" process, production becomes efficient and economically feasible. Additionally, the project's ecological footprint will be minimized through the integration of sustainable, proven materials, while ensuring industrial applicability.

TU Vienna - Institute for Load-bearing Structures, Research Department Reinforced Concrete and Solid Construction

DataB GmbH
Mesh AG

Dr. Tobias Huber
Karlsplatz 13/E212-2, 1040 Vienna
+43 1 58801 21242
tobias.alexander.huber@tuwien.ac.at
www.tuwien.at/cee/tragkonstruktionen/beton