Three-Dimensional Topology Optimization of RC Slabs: Integrating Serviceability and Manufacturing Constraints

This paper presents a novel three-dimensional topology optimization framework for reinforced concrete (RC) slabs that integrates serviceability and manufacturability constraints. Using a density-based Solid Isotropic Material with Penalization (SIMP) approach with filtering and projection, the method generates near-binary topologies while enforcing code-compliant deflection limits and geometric requirements such as minimum rib thickness and spacing. A design example of a 6 m × 6 m slab with corner supports demonstrates that the framework achieves substantial concrete volume reductions compared to conventional solid or ribbed slabs, while ensuring practical constructability. The approach employs morphological filters to maintain adequate member sizes for rebar placement and standard formwork. Numerical results show that weight savings of up to 57% can be realized, underlining the potential for sustainable, cost-effective optimization in real-world slab design.