Bah humbug to you too, pal.
???
... I'm not sure that grav technology is needed to lighten the load. A lot of this depends on materials. ...
Whether or not it's needed is not the question. One can obviously build a ring without it. Point was that by not spinning it, or by spinning it minimally, you put less tension on the ring and can build it larger, but then you'd need the grav generators to supply the gravity that people would expect.
This is an interesting site, a forum where people discuss physics issues, in this case the physics of a habitat ring:
http://cosmoquest.org/forum/archive/index.php/t-111850.html
They suggest a maximum radius of 4.2 kilometers for a steel structure under 1G spin, 14 km for a structure all of titanium, with an adequate built-in safety factor. The steel they discuss assumes a tension strength of 680 MPa, halved for that safety factor; they didn't mention the titanium. They also suggest some exotic materials could do a lot better, but the limiting factor seems to be the tension placed on the material due to the spin needed to provide 1 G. One option they discussed was molecular nanotechnology (MNT) - far future stuff, but I've no idea when it might show up on the Trav tech level progression. Anyway, they suggest this stuff could produce tensile strengths in the vicinity of 5 x 10
10 Pa, which being about a hundred times stronger than steel, produces a structure up to a thousand kilometers in radius (somewhat less after figuring in the mass of the stuff and people living on the ring). They also discussed carbon nanotubes, where apparently there is a potential for tensile strengths in the tens of thousands of MPa.
http://en.wikipedia.org/wiki/Ultimate_tensile_strength
Niven's Ringworld, by comparison, encountered a tension stress of 7 x 10
16 Pa according to this site:
http://www.alcyone.com/max/reference/scifi/ringworld.html
An interesting aside was the discussion of metal fatigue and wear, suggesting that whatever the thing is build of, it needs essentially to be able to be "rebuilt" ever 40 years or so in order to replace materials fatigued from stress, the way you'd rebuild a freeway: in short scheduled stretches every year. We might comfortably double that to 80 years, but it still means the structure needs to be constantly maintaining itself at a cost of 1.25 to 2.5% of its base cost every year.
Lacking any information on the base cost of the materials or the labor involved, I've no way to calculate the cost of the structure or the cost of such maintenance. We could perhaps use the High Guard hull costs as a basis. That's Cr100,000 per dTon, implying an annual maintenance cost of Cr1250 to Cr2500 per dTon. That's High Guard, which assumes grav plates and other such tidbits. Gets real expensive calculating real estate that way.
A better model might be MegaTrav, except that leaves you calculating the hull and then the environmental stuff and such separately, and it does some difficult curve thing after 10,000 dTons to generate hull costs, so I don't know if we can extrapolate just by doing multiples of 1,000,000 or would need to determine their cost formula to calculate larger structures. Still, by doing the multiples, at MCr891 for a million dTons plus MCr4200-7000 for the life support (assuming basic and extended, depending on how much is covered by extended), it's a steal compared to a High Guard hull: less than Cr5000-8000 a dTon, implying annual maintenance costs around Cr60-100 to Cr120-200 a dTon. How much it would actually cost
per person would depend on how generous you were with the real estate (and how much of that real estate is under extended life support): an acre represents about 900 dTons flat ground. The maintenance rate is already ten or twenty times the higher city real estate tax rates; of course a habitat will have many sources of revenue to pay that charge from, but it will also have additional costs such as staff.
The only Trav exotic material I know of is bonded superdense, but it's an armor optimized for absorbing kinetic and electromagnetic energy. There are likely to be building materials that are optimized for tensile strength, and I have no idea what the upper limit there might be.
This site offers an equation to calculate the maximum size based on the tensile strength of the material:
http://www.zyvex.com/nanotech/nano4/mckendreePaper.html#RTFToC18
By comparison, the Babylon 5 station was a basic barrel - an O'Niell cylinder - about 8 kilometers long and maybe a kilometer wide, housing about a quarter million people.