Skip to content

Digital Nervi (2025-04)

Performance‐based Design of Lightweight Isostatic Ribbed Slab with 3D Printed Concrete Formwork

10.1002/suco.70105

 Hua Hao,  Liu Yizhuo, Hovestadt Ludger, He Siyuan, Yao Xiuning, Peng Zixuan,  Zou Yufei, Yang Bo
Journal Article - Structural Concrete

Abstract

The material efficiency of cast-in-situ concrete floor slabs can be significantly improved through topology optimization and 3D-printed formwork. The isostatic ribbed slab (IRS), a legacy of Pier Luigi Nervi, aligns the ribs with the isostatic lines of the principal bending moments. This work introduces the Functional IRS as a cast-in-situ lightweight concrete slab system using 3D-printed permanent formwork. The Functional IRS serves as a compact functional ceiling plenum that integrates skylights and building devices such as air ducts. To create openings in ribs, the coupled pods (formwork) were developed to comply with the material-extrusion 3D concrete printing (3DCP) process. A 1:5 scale mockup with curved supporting walls was constructed to verify the feasibility of the construction method. With supports of irregular shape, optimized IRS saves about 30% of the material compared to grid slab. The lightweight ‘digital Nervi’ slab presents a holistic response to global low-carbon concerns by integrating computational optimization and additive manufacturing.

30 References

  1. Ahmed Ghafur (2023-01)
    A Review of 3D Concrete Printing:
    Materials and Process Characterization, Economic Considerations and Environmental Sustainability
  2. Asensio Javier, Josa Irene, Monserrat Andrea, Fuente Albert (2023-09)
    3D‐Printed Concrete Footbridges:
    An Approach to Assess the Sustainability Performance
  3. Batikha Mustafa, Jotangia Rahul, Baaj Mohamad, Mousleh Ibrahim (2021-12)
    3D Concrete Printing for Sustainable and Economical Construction:
    A Comparative Study
  4. Bedarf Patrick, Szabó Anna, Zanini Michele, Heusi Alex et al. (2022-04)
    Robotic 3D Printing of Mineral Foam for a Lightweight Composite Concrete Slab
  5. Bekaert Michiel, Tittelboom Kim, Schutter Geert (2022-08)
    3D Printed Concrete as Stay-in-Place Formwork:
    Mechanics During Casting and Curing
  6. Breseghello Luca, Hajikarimian Hamed, Naboni Roberto (2024-05)
    3DLightSlab:
    Design to 3D Concrete Printing Workflow for Stress-Driven Ribbed Slabs
  7. Breseghello Luca, Naboni Roberto (2022-05)
    Tool-Path -Based Design for 3D Concrete Printing of Carbon-Efficient Architectural Structures
  8. Burger Joris, Huber Tobias, Lloret-Fritschi Ena, Mata-Falcón Jaime et al. (2022-10)
    Design and Fabrication of Optimised Ribbed Concrete Floor Slabs Using Large-Scale 3D Printed Formwork
  9. Buswell Richard, Silva Wilson, Jones Scott, Dirrenberger Justin (2018-06)
    3D Printing Using Concrete-Extrusion:
    A Roadmap for Research
  10. Chen Yu, Veer Frederic, Çopuroğlu Oğuzhan, Schlangen Erik (2018-09)
    Feasibility of Using Low CO2 Concrete Alternatives in Extrusion-Based 3D Concrete Printing
  11. Gappmeier Peter, Reichenbach Sara, Kromoser Benjamin (2024-03)
    Advances in Formwork Automation, Structure and Materials in Concrete Construction
  12. Hansemann Georg, Schmid Robert, Holzinger Christoph, Tapley Joshua et al. (2020-09)
    Additive Fabrication of Concrete Elements by Robots:
    Lightweight Concrete Ceiling
  13. Huber Tobias, Burger Joris, Mata-Falcón Jaime, Kaufmann Walter (2023-03)
    Structural Design and Testing of Material-Optimized Ribbed RC Slabs with 3D Printed Formwork
  14. Jipa Mihail-Andrei, Dillenburger Benjamin (2022-04)
    3D Printed Formwork for Concrete:
    State of the Art, Opportunities, Challenges, and Applications
  15. Jipa Mihail-Andrei, Giacomarra Federico, Giesecke Rena, Chousou Georgia et al. (2019-06)
    3D Printed Formwork for Bespoke Concrete Stairs
  16. Kontovourkis Odysseas, Tryfonos George, Georgiou Christos (2019-06)
    Robotic Additive Manufacturing (RAM) with Clay Using Topology-Optimization Principles for Tool-Path-Planning:
    The Example of a Building Element
  17. Li Yu, Wu Hao, Xie Xinjie, Zhang Liming et al. (2024-02)
    FloatArch:
    A Cable-Supported, Unreinforced, and Re-Assemblable 3D Printed Concrete Structure Designed Using Multi-Material Topology-Optimization
  18. Liu Dawei, Zhang Zhigang, Zhang Xiaoyue, Chen Zhaohui (2023-09)
    3D Printing Concrete Structures:
    State of the Art, Challenges, and Opportunities
  19. Ma Jiaming, Gomaa Mohamed, Bao Ding, Javan Anooshe et al. (2022-09)
    Print Nervi:
    Design and Construction of a Ribbed Floor System in the Digital Era
  20. Mohammad Malek, Masad Eyad, Ghamdi Sami (2020-12)
    3D Concrete Printing Sustainability:
    A Comparative Life Cycle Assessment of Four Construction Method Scenarios
  21. Mohan Manu, Rahul Attupurathu, Schutter Geert, Tittelboom Kim (2020-10)
    Extrusion-Based Concrete 3D Printing from a Material Perspective:
    A State of the Art Review
  22. Rippmann Matthias, Liew A., Mele Tom, Block Philippe (2018-03)
    Design, Fabrication and Testing of Discrete 3D Sand-Printed Floor Prototypes
  23. Tay Yi, Panda Biranchi, Paul Suvash, Mohamed Nisar et al. (2017-05)
    3D Printing Trends in Building and Construction Industry:
    A Review
  24. Voney Vera, Odaglia Pietro, Brumaud Coralie, Dillenburger Benjamin et al. (2021-02)
    From Casting to 3D Printing Geopolymers:
    A Proof of Concept
  25. Wan Qian, Yang Wenwei, Wang Li, Ma Guowei (2023-04)
    Global Continuous Path-Planning for 3D Concrete Printing Multi-Branched Structure
  26. Wangler Timothy, Roussel Nicolas, Bos Freek, Salet Theo et al. (2019-06)
    Digital Concrete:
    A Review
  27. Wang Li, Yang Yu, Yao Liang, Ma Guowei (2022-02)
    Interfacial Bonding Properties of 3D Printed Permanent Formwork with the Post-Casted Concrete
  28. Xiao Jianzhuang, Ji Guangchao, Zhang Yamei, Ma Guowei et al. (2021-06)
    Large-Scale 3D Printing Concrete Technology:
    Current Status and Future Opportunities
  29. Yu Qian, Zuo Qinxin, Zhang Yamei, Pan Jinlong (2024-08)
    An Investigation on Enhancing the Bonding Properties of 3D Printed Concrete Permanent Formwork and Post-Casted Concrete
  30. Zhu Binrong, Nematollahi Behzad, Pan Jinlong, Zhang Yang et al. (2021-04)
    3D Concrete Printing of Permanent Formwork for Concrete Column Construction

1 Citations

  1. Lin Xing-Tao, Xu Shuhao, Chen Xiangsheng (2025-08)
    Optimization of Building Structures Based on Additive Manufacturing:
    A Review

BibTeX 
@article{hua_liu_hove_he.2025.DN,
  author            = "Hao Hua and Yizhuo Liu and Ludger Hovestadt and Siyuan He and Xiuning Yao and Zixuan Peng and Yufei Zou and Bo Yang",
  title             = "Digital Nervi: Performance‐based Design of Lightweight Isostatic Ribbed Slab with 3D Printed Concrete Formwork",
  doi               = "10.1002/suco.70105",
  year              = "2025",
  journal           = "Structural Concrete",
}
Formatted Citation

H. Hua, “Digital Nervi: Performance‐based Design of Lightweight Isostatic Ribbed Slab with 3D Printed Concrete Formwork”, Structural Concrete, 2025, doi: 10.1002/suco.70105.

Hua, Hao, Yizhuo Liu, Ludger Hovestadt, Siyuan He, Xiuning Yao, Zixuan Peng, Yufei Zou, and Bo Yang. “Digital Nervi: Performance‐based Design of Lightweight Isostatic Ribbed Slab with 3D Printed Concrete Formwork”. Structural Concrete, 2025. https://doi.org/10.1002/suco.70105.