Rethinking Concrete Slabs: Modular CFRP-Reinforced Systems for Sustainable Construction

A significant portion of concrete in building construction is allocated to traditional solid slabs, resulting in excessive material use and substantial CO2 emissions. Modular ribbed CFRPreinforced floor slab systems offer an efficient alternative, significantly reducing material use while maintaining structural performance. However, fabricating such ribbed structures is challenging, particularly regarding complex formwork and labor-intensive processes. Innovations in 3D concrete printing provide a solution by enabling the straightforward production of novel, load-adapted concrete structures, disrupting conventional construction practices. This paper presents a concept for a modular floor slab system that integrates topology-optimized design principles with digital manufacturing methods. Slender, bi-directionally oriented ribs are 3D-printed onto a thin precast base slab, creating lightweight, geometrically adaptable slab modules. These modules are designed with detachable dryjoint connections for mechanical assembly through post-tensioning, which ensures reusability. A prototype comprising five integrated modules validated the efficacy of digitally fabricated slab system. This demonstration successfully bridges ecological responsibility with cutting-edge digital fabrication techniques, establishing a groundbreaking paradigm for sustainable construction practices.