3DLightSlab. Design to 3D concrete printing workflow for stress-driven ribbed slabs

Abstract

In addressing the critical need to lower CO2 emissions in concrete construction, where slabs represent 43% of embodied carbon in midrise buildings, this study presents an innovative approach utilising 3D Concrete Printing (3DCP). We introduce 3DLightSlab, a carbon-efficient design for load-bearing slabs that leverages stress-driven design to generate isostatic ribs that adapt to diverse shapes, support arrangements, and load conditions, optimising structural layout and material efficiency. A case study demonstrates the design and fabrication of a slab supported by two columns tailored to withstand combined loads. Our methodology integrates Finite Element Analysis (FEA) for precise rib dimensionsing and density adjustment. The study includes the 3DCP of steel-reinforced prototypes, which were tested in 3-point bending and validated against Eurocode standards for serviceability, confirming the structural integrity of the slab under anticipated loads. This investigation demonstrates the potential of 3DCP in producing structurally sound, carbon-efficient horizontal structures, marking a significant step towards sustainable construction practices.