Structural design with uncertainties of coreless filament wound structures

Lightweight structures and efficient fabrication methods that reduce environmental impact in the construction sector attract increasing attention. Fibre-polymer composites (FPCs), such as carbon and glass fibres, have been investigated for such potential, while natural fibres have emerged as a low‑carbon alternative. These materials have been demonstrated in real-scale experimental projects and research pavilions, particularly when fabricated with Coreless Filament Winding (CFW). Despite the proven viability, the structural design of fibre components remains challenging due to material variability, geometric irregularities, and the reliance of safety evaluation on physical testing. This work presents a design feedback method for a CFW structural component that includes uncertainties in the CFW component. The method uses FE simulation incorporating material variations and deriving a design load factor to amplify the design load accounting for this variability. The integration of probabilistic analysis improves the reliability of the design feedback, while structural safety is ultimately verified through full‑scale load testing. • CFW components exhibit large uncertainties which require stochastic approaches. • Probabilistic analysis reveals unconservative design results of CFW component. • Destructive test validates the design approach and proves the safety. • A design load factor amplifies load to represent the influence of uncertainty. • Simplified FEM with a design load factor provides better computation efficiency.