Thermoplastic fiber-reinforced polymer composites in construction: A state-of-the-art review

Thermoplastic fiber-reinforced polymer (TP-FRP) composites are increasingly utilized across aerospace, automotive, and construction sectors. Despite their expanding applications, comprehensive reviews on TP-FRP composites in construction remain scarce. This paper provides a systematic synthesis of current research and applications of TP-FRP composites in the construction industry. The review begins by addressing the molecular characteristics of thermoplastic resin matrices and different manufacturing processes for these composites, including non-reactive and reactive routes. The reactive routes are highlighted for their significant enhancement in fiber impregnation quality and thus fiber-resin interfacial properties. The structural implementations and performance validation of these composites in construction are then analyzed, spanning from non-structural components to load-bearing members. The review then focuses on the mechanical properties of TP-FRP bars, synthesizing data from both short-term and long-term tests, including recent findings from the authors’ group. The evidence indicates that acrylate-based TP-FRP bars fabricated via the reactive process exhibit superior short-term performance and long-term durability. Finally, the paper identifies critical research gaps, including limited studies on structural-scale TP-FRP components and bond-slip behaviors for design standardization. Future research endeavors should focus on expanding the range of in-situ polymerization materials, optimizing bendability of TP-FRP bars through pre-tension protocols, and establishing robust predictive models for their lifecycle performance.