Revolutionizing concrete reinforcement: An innovative 3D FRP system for sustainable construction of complex geometries

This research presents a novel 3D fiber-reinforced polymer (FRP) system intended for the casting and reinforcement of concrete components with intricate geometrical configurations. The system addresses critical challenges associated with traditional reinforcement methods, such as premature debonding of flexural FRP, high concrete consumption, inefficient FRP utilization, etc. A series of experiments were conducted using prism, Tshaped, and non-prism specimens. Prism tests focused on identifying optimal anchorage configurations, including both bent anchorage and U-shaped wrap, with the aim of optimizing the use of wet-bonding FRP reinforcements. T-shaped and non-prism specimens were tested to evaluate the performance of the 3D FRP system in terms of load capacity, concrete usage, and FRP strength. The results showed that the 3D FRP system made fuller use of flexural FRPs and delayed the debonding failure. T-shaped specimens with one or two layers of FRP reinforcements achieved similar load-deflection results and capacities as prisms while using only 57 % of the concrete. Non-prism specimens also demonstrated potential for reducing concrete without significant compromise in load capacity. The U-shaped wraps and epoxy-saturated tissues enhanced the structural rigidity of the 3D FRP formwork, thereby enabling the casting of complex geometrical shapes. The research therefore opens new directions for future studies in optimizing 3D FRP applications for complex structural geometries, promoting more resilient and efficient construction methods.