Bond behavior between surface-treated 3D-printed FRP bars and concrete
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(Published version)
Date
2026
Authors
Yan, Z.-T.
Hu, X.
Zhou, J.-K.
Zhuge, Y.
Zeng, J.-J.
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Composite Structures, 2026; 381:120051-1-120051-17
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Zi-Tong Yan, Xianwen Hu, Jie-Kai Zhou, Yan Zhuge, Jun-Jie Zeng
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Abstract
Fiber-reinforced polymer (FRP) bars have been widely adopted as internal reinforcement for concrete structures, however, the conventional pultrusion fabrication process imposes limitations including reliance on molds and material waste. To address these issues, an innovative form of 3D-printed FRP (3DP-FRP) reinforcing bars based on additive manufacturing has recently been developed by the authors. In this study, a novel surface treatment for 3DP-FRP bars using serrated cross-section and sand coating is developed to enhance the bar-concrete interfacial bond performance. A total of 33 pull-out tests were performed to systematically investigate the effects of surface treatment methods, concrete strength, anchorage length, and bar diameter on the bond behavior of 3DP-FRP bars in concrete. Results show that untreated 3DP-FRP bars achieve a bond strength (the maximum average shear stress along the bonded length) of up to 7.3 MPa, markedly exceeding that of smooth pultruded bars. The bond strength increases with concrete strength but decreases with a greater anchorage length or bar diameter. The bars with a helical wrap and coarse sand coating (HWCS) exhibit the highest bond strength. Furthermore, the applicability of the modified BPE (mBPE) model for bond-slip characterization of 3DP-FRP bars is validated, and a new predictive equation for bond strength estimation is proposed.
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© 2026 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).