Innovative Use of UHPC and Topology Optimization in Permeable Interlocking Pavers: Advancing Sustainable Pavement Solutions

The rapid expansion of urban areas has increased the prevalence of impermeable surfaces, intensifying flooding risks by disrupting natural water infiltration. Permeable pavements have emerged as a sustainable alternative, capable of reducing stormwater runoff, improving surface friction, and mitigating urban heat island effects. Nevertheless, their broader implementation is often hindered by issues such as clogging and limited mechanical strength resulting from high porosity. This study examines the design of interlocking permeable blocks utilizing ultra-high-performance concrete (UHPC) to strike a balance between enhanced drainage capacity and high structural performance. A topology optimization (TO) strategy was applied to numerically model the ideal block geometry, incorporating 105 drainage channels with a diameter of 6 mm—chosen to ensure manufacturability and structural integrity. The UHPC formulation was developed using particle packing optimization with ordinary Portland cement (OPC), silica fume, and limestone filler to reduce binder content while achieving superior strength and workability, guided by rheological assessments. Experimental tests revealed that the perforated UHPC blocks reached compressive strengths of 87.8 MPa at 7 days and 101.0 MPa at 28 days, whereas the solid UHPC blocks achieved compressive strengths of 125.8 MPa and 146.2 MPa, respectively. In contrast, commercial permeable concrete blocks reached only 28.9 MPa at 28 days. Despite a reduction of approximately 30.9% in strength due to perforations, the UHPC-105holes blocks still far exceed the 41 MPa threshold required for certain structural applications. These results highlight the mechanical superiority of the UHPC blocks and confirm their viability for structural use even with enhanced permeability features. The present research emphasizes mechanical and structural performance, while future work will address hydraulic conductivity and anticlogging behavior. Overall, the findings support the use of topology-optimized UHPC permeable blocks as a resilient solution for sustainable urban drainage systems, combining durability, strength, and environmental performance.