Utuzuu: as far as I recall habitats do not give me an advantage when it comes to output versus empire sprawl. Please correct me if I am wrong.
The issue is how much sprawl it costs to support researcher jobs. While research labs don't cost sprawl on their own, you do need city districts to house the researchers, and elsewhere you will need city districts to house the workers who make the consumer goods and exotic gasses that are used by the researchers, and then there's some overhead for the planet itself. When you add it all up it comes out to about 4.5 researchers for every 1 point of sprawl. When you calculate it out for research districts in habitats, it's only about 1.5 researchers for every 1 point of sprawl.
I've done a lot of spreadsheeting, and have basically concluded that for very large empires sprawl management is just as important as how much science you're outputting. In particularly extreme cases, you can actually end up
reducing your science output by adding more researchers if you added too much sprawl in the process!
Utuzuu: Even if they were a way to effectively reduce empire sprawl versus output, during most of my games I research Administrative Capacity to levels beyond 100, with research time per level being around 12 months with egalitarian empires. Other empires I have played around with, but I have difficulties finding a viable late game research strategy without the egalitarian option of utopian living standards.
I've been doing much the same, although in my experience you can usually just go to war and claim enemy worlds to fill your expanding admin cap, so it's not like you've got room to waste. And if you're doing this you
do not want to go over your admin cap even a little (you're literally better off abandoning territory than going over admin cap at these scales). As far as science on habitats go, unemployed pops are
way, way better than science districts.
As for producing science without utopian abundance, the trick is just to build
lots and lots of labs.
Utuzuu: In fact, I once conquered an AI with an absurd amount of habitats, but they were such a drain on my economy that I just went on to resettle everyone to my ring worlds and arcologies and proceeded to wipe out the remaining habitats with my colossus. Fun fact: I was not aware of the diplomatic penalty this course of action would incure from other empires. They mad, bro.
There shouldn't be a penalty for doing this, not unless you purged them. Just resettling them off the habitats (which you should definitely do; the AI builds
way too many habitats) doesn't piss anyone off.