Precast hollow core slabs (HCS) are technically advanced products in the precast concrete industry, widely used in the last years due to their versatility, their multipurpose potential and their low cost. Using three dimensional FEM (Finite Element Method) elements, this study focuses on the stresses induced by the prestressing of steel. In particular the investigation of the spalling crack formation that takes place during prestressing is carried out, since it is important to assure the appropriate necessary margins concerning such stresses. In fact, spalling cracks may spread rapidly towards the web, leading to the detachment of the lower part of the slab. A parametric study takes place, capable of evaluating the influence of the tendon position and of the web width on the spalling stress. Consequently, after an extensive literature review on the topic of soft computing, an optimization of the HCS is performed by means of Genetic Algorithms coupled with 3-D FEM models.