Types Of Fiber Reinforced Polymer Research Articles

Finite Element Analysis of Two-Way Reinforced Concrete Slabs Strengthened with FRP Under Flexural Loading

This paper presents a finite element (FE) model of reinforced concrete two-way slab strengthened using fiber-reinforced polymer (FRP) sheets. This model was validated against experimental data from the literature and it showed acceptable prediction accuracy. Although carbon-FRP (CFRP) is the most commonly used composite in repairing and strengthening reinforced concrete structures, it is important to consider other types of FRP composites such as the eco-friendly basalt-FRP (BFRP) and the newly developed polyethylene terephthalate-FRP (PET-FRP). Therefore, the validated FE model was utilized to perform a parametric study for slabs having different values of concrete compressive strength (ranging from 20 to 80 MPa) and strengthened with other types of FRP. The results show that CFRP provides the highest strength enhancement with a 34.5% increase in the ultimate load, while PET-FRP provides the lowest improvement with an increase of 11.2%, compared with unstrengthened slab. The results also show that the concrete compressive strength (fc’) has moderate influence on the ultimate load. For example, increasing fc’ from 20 MPa to 80 MPa increased the predicted ultimate load for CFRP-strengthened slab from 15% to 62%. The FE model provides a suitable prediction for the ultimate strength and deformability of the strengthened two-way slabs that helps in better understanding of the performance of strengthened slabs and allows engineers to optimize design parameters.

Seismic performance of FRP-repaired RC piers after blast loading

Aiming to evaluate the effectiveness of fiber-reinforced polymer (FRP) repair on the seismic performance of blast-damaged reinforced concrete (RC) piers, the field test and numerical simulation were conducted. Firstly, a successive field explosion test, carbon FRP (CFRP) repair, and lateral cyclic loading test were performed on two 1/2-scale RC pier specimens. The test data including the incident overpressure-time histories of blast wave, damage profiles and lateral force-displacement relationships of pier specimens, etc. were comprehensively recorded and discussed. By comparing with the previous blast-damaged pier specimen, the negative maximum force and ductility of CFRP-repaired pier were increased by 97 % and 44.9 % after 1.0 kg TNT explosion, respectively. Then, an integrated numerical simulation approach based on explicit-implicit switching and full restart algorithms was proposed and validated in predicting the dynamic and quasi-static behaviors of RC piers under successive blast loading, CFRP repair, and lateral cyclic loading. Finally, a prototype RC pier was designed and the suicide vest bomb (TNT equivalence of 9 kg) specified by the Federal Emergency Management Agency was selected as the threat of contact explosion. The influences of FRP type, repair height, and number of FRP layer on restoring the seismic performance of the blast-damaged pier were further discussed. It indicates that, (i) CFRP is more effective than glass FRP and aramid FRP; (ii) increasing the repair height could not significantly improve the seismic performance of pier; (iii) the number of FRP layer has significant effect, e.g., the positive and negative maximum forces after 4-layer CFRP repair are improved by 9.4 % and 45.3 % compared to the unrepaired pier, respectively. The present study could provide a helpful reference for assessing the FRP repair effectiveness on the seismic performance of blast-damaged RC bridge piers.

Behavior of FRP-interlayer-steel confined concrete columns subjected to eccentric compression

Fiber reinforced polymer (FRP)-interlayer-steel confined concrete (FISC) columns are proposed by bonding a filament-wound FRP tube with a concrete-filled steel tube (CFST) using grouting material to increase the corrosion resistance of CFST columns. FISC columns have high bearing capacity, benefiting from the dual confinement provided by both FRP and steel tubes on the core concrete. Despite this, the current research on the behaviors of FISC columns is limited, particularly regarding the confinement mechanism in FISC columns under eccentric compression. In this paper, a total of twenty short specimens were tested under eccentric compression, including seventeen FISC specimens, two FRP confined concrete-filled steel tubular (CCFT) columns, and one CFST specimen. Failure modes, load versus deflection curves and strain development for FISC specimens were presented and discussed, considering variations in eccentricity, FRP types, FRP thicknesses, and the ratio of FRP and steel confining indexes. Additionally, confining stresses of the FRP and steel tubes were obtained, revealing a non-uniform distribution of confinement on concrete along the sectional circumference, which decreased with increasing eccentricity. Furthermore, by regarding the concrete and grouting material as a whole unity and accounting for the influence of eccentricity, a sectional numerical analysis model for FISC columns was established and validated against test results, and the influences of steel thickness, FRP thickness, and concrete-grouting strength on the N-M correlation curves of FISC columns were investigated.

Stress-strain modelling of circular concrete-filled FRP–steel composite tube columns under axial compression load

Concrete filled-circular steel tube (CFCST) columns, when externally confined with carbon or glass fiber-reinforced polymers (FRP) sheets and subjected to axial load, exhibit improved strength and ductility compared to unconfined cases. The mechanical properties of the confinement materials are crucial in determining the stress-strain relationship of the confined concrete. This study presents an in-depth analysis of the stress-strain behavior of FRP-confined CFST columns, based on data from 252 specimens. It examines a range of factors, including various infill concrete grades from 14.15 to 140.39 MPa, two types of carbon steel outer tubes with yield strengths (fy) from 226 to 466.5 MPa, and two types of FRP (CFRP and GFRP) with tensile strengths from 1260 to 4900 MPa. The complete axial stress-strain curve is divided into four phases according to a mathematical expression by Wu and Wei (2015): the elastic phase, nonlinear transition phase, linear softening phase, and residual phase. New formulas for ultimate stress, based on confinement stress, were proposed by Hassanin et al. (2023), while the ultimate strain was calculated using the classical formula by Richart et al. Peak stress and strain were determined through statistical linear regression analysis using SPSS software, based on 252 experimental data points and involved using a combined factor of steel contribution (Elsfco) and FRP contribution (Elffco). Eight specimens were specifically used to validate the models through Finite Element Method (FEM) simulations. The accuracy of the predicted analysis results was also assessed by comparing them to existing models. The evaluation showed that the models successfully simulated the complete stress-strain curve of FRP-wrapped CFST columns under axial load, producing satisfactory results. These four models provide reliable results for calculating ultimate stress, ultimate strain, peak stress, peak strain, and the complete stress-strain behavior of these columns.

Effect of heat aging on pull-off strength of FRP epoxy bonded concrete: An experimental study and fire modelling

In this study, the bonding strengths of three different types of externally bonded composite systems were investigated under different environmental aging conditions at high temperatures, and the finite element model for a roof fire and concrete slab fire from above evaluated if the beams were externally reinforced with fiber-reinforced polymers (FRP). An FRP system is a structural reinforcement made of a type of fiber reinforcement fixed to a concrete surface through an epoxy adhesive. The bonding strength between the FRP and concrete substrates was measured using a pull-off test machine, as described in the EN 1542 standard. This study aims to determine the deterioration and negative effects of miscellaneous high temperatures on externally bonded FRPs used for strengthening civil structures. Epoxy-bonded carbon fiber-reinforced polymers (CFRP), glass fiber-reinforced polymers (GFRP), and basalt fiber-reinforced polymers (BFRP) were exposed to various temperatures of 23°C (control conditions), 70, 85, 100, 115, 130, and 150°C. Duratek® AV21 epoxy-based lamination system was used as an adhesive between the concrete and the FRP sheet. Three bonding failure modes (adhesive, cohesive, and substrate) were investigated for each test. The results were compared for three different types of FRPs under various temperatures, which is also significant research on the heat aging of the degradation process. The test results were also evaluated using finite element (FE) software modelling for roof and slab fires exposed from above, where the beams under the slab were reinforced with FRP systems. The test pull-off test results and FE model thermal analysis results were evaluated to obtain the temperature rise in the critical section of the concrete beam/slab in existing retrofitted buildings. The FE model results showed a critical temperature rise on the beam-slab corner connection as a result of the fire above the concrete slab. The duration of the FRP systems effectively bonded to the concrete beams located under different slab thicknesses and pull-off results were evaluated at elevated temperatures.

Predictive modeling of aramid fiber reinforced polymer confinement for improved compressive strength in circular concrete columns

Fiber Reinforced Polymers (FRPs) have gained significant attention in the field of structural engineering due to their high strength-to-weight ratio, corrosion resistance, and ease of application. Among various types of FRPs, Aramid Fiber Reinforced Polymers (AFRP) stand out for their exceptional tensile strength and durability, making them ideal for confining concrete columns to enhance their compressive strength. This study aims to leverage these benefits by predicting the compressive strength of circular concrete columns confined with AFRP using Artificial Neural Networks (ANNs). To develop and validate the ANN model, a comprehensive dataset consisting of 190 samples was employed during the training phase, while an additional set of 33 samples was used for validation. The performance and predictive capabilities of the ANN model were thoroughly assessed through extensive testing and direct comparison with experimental results, which demonstrated the model’s high accuracy and reliability. Moreover, a detailed parametric study was conducted to examine the influence of various input parameters on the compressive strength prediction. The findings from this study offered significant insights into the effects of various parameters on the predicted outcomes, including column diameter, unconfined concrete strength and strain, as well as AFRP confinement parameters such as thickness, tensile strength, elastic modulus, and strain. Notably, the sensitivity analysis underscored the profound impact of the tensile strength of AFRP on the ANN model's predictive accuracy. The research offers a robust tool for engineers, enabling them to estimate the compressive strength of AFRP-confined circular concrete columns accurately. Additionally, it provides crucial insights that are instrumental in optimizing the design and application of AFRP wrapping or tube-encased methods within the realm of structural engineering. Overall, this research marks a significant step forward in the field of structural engineering, providing a valuable predictive tool and offering insights that can lead to the development of more resilient and sustainable infrastructure.

Transient state analysis of rehabilitated RC beams using finite element modelling and prediction using an artificial neural network

The present research develops and verifies a simpler numerical approach for analyzing the thermal transient state of rehabilitated concrete beams reinforced with various types of FRP (fiber-reinforced polymer) subjected to high temperatures and specifically built as under-reinforced concrete beams. This approach offers a straightforward, efficient, and exact instrument for numerical analysis. The proposed analytical technique has been validated by load-displacement curves and cross-section temperature data, indicating its dependability and practicality. Subsequently, the validated approach was used to examine the impact of significant variables on the outcome and restoration of FRP-reinforced concrete beams at high temperatures. The methodology gives the Comparing conventional and CFRP, GFRP, AFRP reinforced beams using beam, truss, and shell elements. Thermal and UDL loads were applied, mesh at 25 mm × 25 mm. Transient analysis contrasts performance via displacement and temperature. The temperature versus displacement curve shows the FRP comparisons. Identifying the critical temperature before failure is crucial, emphasizing the curve’s significance in assessing structural performance and potential failure points. Nodal temperatures ranged 939 °C–963 °C (rehabilitated) versus 958 °C (conventional). 200 °C difference affects thermal boundary conditions for structural analysis and Conventional peaks at 320 °C, while AFRP, GFRP, and CFRP reach 358 °C, 385 °C, and 390 °C respectively. CFRP lasts 2400 min. Neural network models demonstrate effective generalizability, enabling satisfactory predictions of RC beam rehabilitation with CFRP laminates within the study’s parameter range.

Damage Detection in FRP-Reinforced Concrete Elements.

Fiber-Reinforced Polymer (FRP) composites have emerged as a promising alternative to conventional steel reinforcements in concrete structures owing to their benefits of corrosion resistance, higher strength-to-weight ratio, reduced maintenance cost, extended service life, and superior durability. However, there has been limited research on non-destructive testing (NDT) methods applicable for identifying damage in FRP-reinforced concrete (FRP-RC) elements. This knowledge gap has often limited its application in the construction industry. Engineers and owners often lack confidence in utilizing this relatively new construction material due to the challenge of assessing its condition. Thus, the main objective of this study is to determine the applicability of two of the most common NDT methods: the Ground-Penetrating Radar (GPR) and Phased Array Ultrasonic (PAU) methods for the detection of damage in FRP-RC elements. Three slab specimens with variations in FRP type (glass-, carbon- and basalt-FRP, i.e., GFRP, CFRP, and BFRP, respectively), bar diameter, bar depths, and defect types were investigated to determine the limitations and detection capabilities of these two NDT methods. The results show that GPR could detect damage in GFRP bars and CFRP strands, but PAU was limited to damage detection in CFRP strands. The findings of this study show the applicability of conventional NDT methods to FRP-RC and at the same time identify the areas with a need for further research.

Strengthening of slender webs of steel plate girders using FRP composites

Web buckling of steel plate girders creates an undesirable failure mode as it can limit the ultimate load capacity of plate girders. This paper presents details of an experimental investigation aimed at strengthening slender end panels of steel plate girders using three different types of fibre-reinforced polymer (FRP) composite materials (glass-fibre-reinforced polymer (GFRP) pultruded section stiffeners and woven carbon-fibre-reinforced polymer (CFRP) and GFRP fabrics). The plate girders were fabricated using non-rigid end posts and were tested in three-point bending. The test results showed an increase of up to 54% in the ultimate strength of the FRP-strengthened end panels compared with the non-strengthened control panel, which was the result of increased out-of-plane stiffness of the web. A breakdown of the bond between the steel and the FRP fabric occurred in the end panels strengthened with CFRP and GFRP fabrics, while no bond breakdown of the pultruded sections was observed at the ultimate load. Analytical methods proposed by some of the design codes underestimated the critical buckling load and overestimated the ultimate load of the non-strengthened end panel.

Evaluation of Ultimate Axial Strain Models for Fiber-Reinforced Polymer-Confined Concrete Cylinders

Fiber-reinforced polymer (FRP) composite has been widely applied to reinforce and rehabilitate concrete columns in civil engineering. It is necessary to deeply understand the ultimate deformation (i.e., the ultimate axial strain εcc ) of FRP-confined concrete columns. A large database including different types of FRP (conventional FRP and large-rupture-strain FRP), concrete compressive strengths (19.4 MPa-169.7 MPa), and cylinder sizes (51 mm-508 mm), as well as various concrete types, is collected in this study. For this reason, several existing ultimate axial strain modes for FRP-confined cylinders have been evaluated via some statistical parameters based on the database. The verification results illustrate that the prediction accuracy of axial strain models is not good enough due to the intrinsic difficulty in predicting deformation and variability of data source, although the available models with better performance can achieve the average ratio between experimental and predicted strain value ( εccexpe/εccpred ) below 10%.

Compressive Performance of Longitudinal Steel-FRP Composite Bars in Concrete Cylinders Confined by Different Type of FRP Composites.

This paper presents an experimental study on the compressive performance of longitudinal steel-fiber-reinforced polymer composite bars (SFCBs) in concrete cylinders confined by different type of fiber-reinforced polymer (FRP) composites. Three types of concrete cylinders reinforced with (or without) longitudinal SFCBs and different transverse FRP confinements were tested under monotonic compression. The results showed that the post-yield stiffness of SFCBs is higher when confined with high elastic modulus carbon fiber-reinforced polymer (CFRP) composite than with low elastic modulus basalt fiber-reinforced polymer (BFRP) composite. Decreasing confinement spacing did not significantly improve the compressive strength of SFCBs in concrete cylinders. The compressive failure strain of SFCBs could possibly reach 88% of its tensile peak strain in concrete cylinders confined by CFRP sheets, which is significantly higher than the value (around 50%) in previous studies. Existing design equations, which applied a strength reduction factor or a maximum compressive strain of concrete to consider the compressive contributions of SFCBs in concrete members, underestimate the load-carrying capacity of SFCB-reinforced concrete cylinders. The design equation that considers the actual compressive stress of SFCBs gives the most accurate prediction; however, its applicability and accuracy need to be verified with more experimental data.

Behavior of grouted splice sleeve connection using FRP sheet

Most existing studies on grouted splice connections have focused on the bond behavior between connected steel rebars and conventional steel or iron sleeves. These research findings cannot properly predict the bond behavior and performance of the grouted splice connections, particularly when a new splice device, such as fiber reinforced polymer (FRP) materials, are adopted. The main purpose of this study is to investigate the feasibility of the proposed grouted splice sleeve connection (GSSC) using sheet materials of carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP). A total of 45 GSSC specimens with various rebar embedded lengths and different polymer sleeve materials were tested to failure under incremental axial pull-out load to evaluate the bond performance of the connected steel rebars in confined grout provided by the FRP sleeves. To evaluate the confinement effect of FRP sleeves on the tensile strength of the grouted connection, an analytical model was developed. The pull-out test results showed that the rebar embedded length was the major parameter affecting the average tensile strength of the GSSC. Also, the effects of mechanical properties of FRP sheets, such as the number of FRP layers and type of FRP sheets, contributed to the tensile strength of the GSSC sleeves that allow the transmission of tensile load between rebars through the medium of grout, aluminum tube, and FRP sheets. The analytical model that incorporates the confinement effects predicted well the experimental ultimate tensile strength of GSSC connections.

Flexural Behavior of Reinforced Concrete Voided Slabs Strengthened with Different Types of FRP: State-of-the-Art Review

Some reinforced concrete slabs may require rehabilitation or strengthening due to load increment caused by a change in the function for which they were built or unintentional errors during design or execution. There are numerous techniques for such problems. The rehabilitation or strengthening of structural members using fiber-reinforced polymer (FRP) is one of the most recent techniques. This technique is widely spread due to its high tensile strength and lightweight; also, the thickness of the strengthened structural member decreases when these materials are used. This paper provides a comprehensive review of several strengthening techniques in terms of their results, advantages, and the extent of their effect on the flexural behavior of voided concrete slabs. Research has shown that this type of strengthening contributes to improving the slabs’ performance, as it contributes to increasing the first crack load and the ultimate load, and it contributes to decreasing the value of the deflection corresponding to the ultimate load and improves the ductility and toughness of these slabs. Also, the flexural strength of these slabs increases with the number of strengthening layers used. CFRP is one of the best types of FRP. It was found that the presence of voids caused a decrease in the flexural strength and an increase in the deflection value; however, the process of strengthening with polymer fibers for this type of slab recovers and compensates for losses from the presence of voids.

Constitutive Model of FRP Tube-Confined Alkali-Activated Slag Lightweight Aggregate Concrete Columns under Axial Compression

Fiber reinforced polymer (FRP), as a novel type of composite material, has been extensively employed in structural strengthening and composite structures. The FRP tube-confined alkali-activated slag lightweight aggregate concrete column (FRP-AASLAC) can effectively improve the utilization rate of slag, reduce carbon emissions, reduce structural self-weight, and improve structural ductility. Therefore, the axial compressive properties of FRP-AASLAC were studied in this paper. The influences of the type of FRP, FRP thickness and the content of lightweight aggregate on the failure modes, bearing capacities, deformation properties and constitutive relationships of FRP-AASLAC were revealed. The results indicate that the constitutive relationships of FRP-AASLAC show double broken line patterns without obvious softening sections. The restraining effect of FRP on lightweight aggregate concrete is higher than that on ordinary concrete as lightweight aggregate concrete has lower strength and more easily undergoes lateral expansion under external loads. Models for compressive strength, peak compressive strain and constitutive relationship for FRP-AASLAC are proposed.

Behaviour of reinforced concrete corbels strengthened by FRP composites and steel bars: a critical review

In reinforced concrete (RC) structures, corbels that extend from the faces of reinforced concrete columns are commonly employed to support primary beams and girders. Frequently, the use of corbels is limited to cantilevers with a shear span-depth ratio that is often less than 2. Because of this relatively low ratio, corbel strength is normally dominated by shear, which is comparable to deep beams. However, owing to some reasons (e.g., design and/or construction faults, modification of facility use, deterioration, and aging), strengthening of existing corbels is becoming of prime importance. The aim of the present paper is to conduct a critical review of commonly proposed techniques that have been implemented to strengthen RC corbels. These techniques comprised near surface mounted (NSM) steel bars, NSM fibre reinforced polymer (FRP) bars, and FRP sheets. The latter strategy included carbon (CFRP) and glass (GFRP) sheets. Hybrid strengthening (combining FRP sheets and FRP/steel bars) was also highlighted in this paper. The strengthened (upgraded) RC corbels were evaluated considering several parameters, including shear span to depth ratio (a/d), quantity and configuration of reinforcement, FRP type, and levels of damage in the tested specimens.

Experimental assessment and effective bond length for RC columns strengthened with aramid FRP sheets under cyclic loading

Fiber reinforced polymer (FRP) materials continue to demonstrate outstanding performance for strengthening and repairing reinforced concrete structures. However, one of the most significant problems that still has to be tackled is premature failure brought on by the FRP debonding. This research sought to determine how damaged RC columns could be strengthened with aramid (one type of FRP) composites and how that would affect their seismic responses. To further understand the individual effects of each strengthening material on seismic performance, hysteretic responses, such as strength, ductility, and energy dissipation, were examined and compared. Analytical modeling is validated based on the experimental results. Experimental results are validated with comparative study against other solid experimental results within the broader field. Effective bond length (EBL) is crucial for understanding the bonding between aramid fibers and concrete, however various models have different ways of calculating the value of EBL. Therefore, this research examined earlier experimental investigations of EBL and employing finite element (FE) methods established a novel relationship between the EBL and the aramid-to-concrete bond, based on experimental results.

Cyclic Stress–Strain Behavior and Model for FRP-Confined Engineered Cementitious Composite

A fiber-reinforced polymer (FRP) confined engineered cementitious composite (ECC) column as a new high-performance composite member achieves significant ductility. Understanding its cyclic behavior is necessary to guide seismic design. This paper presents an experimental study on the compressive behavior of large rupture strain (LRS) FRP and traditional glass FRP (GFRP) jacketed ECC cylinders subjected to full and partial cyclic loadings. Effects of FRP confinement level, FRP type, and loading scheme on the failure pattern, stress–strain relationship, ultimate condition, plastic strain, and stress deterioration ratio were examined. Existing equations for plastic strain and stress deterioration ratio of the envelope and internal cycles were evaluated. Based on the experimental results, new calculation formulas were derived for the plastic strain and stress deterioration ratio. A threshold involving partial unloading/reloading factors was determined to define the effective cycles. In addition, a cyclic model composed of a monotonic envelope model and an unloading/reloading model was developed for estimating the stress–strain hysteresis loops of both GFRP- and LRS FRP-confined ECC cylinders.

Seismic behavior of RC square columns strengthened with LRS FRP under high axial load ratio

A new type of fiber-reinforced polymer (FRP) with a tensile rupture strain of more than 5% was used for the seismic retrofitting of reinforced concrete (RC) square columns in this paper. A control column and 9 FRP-wrapped RC square columns were prepared with different number of FRP layers and FRP types. The seismic performance was comprehensively discussed and analyzed in terms of the failure modes, hysteretic behaviors, cumulative energy dissipation and FRP strain evolution. Experimental results showed that the ductility of specimens had a remarkable improvement as the confinement stiffness increased. Moreover, the buckling of longitudinal bars was restricted and postponed. Numerical analysis was conducted in OpenSees to further research the seismic performance of specimens based on an LRS FRP-confined concrete model and a reinforcing bar buckling model considering FRP confining effect. The simulated results were in close agreement with the experimental results. Parametric analysis was also conducted to investigate the influence of the FRP wrapping thickness, axial compression ratio and longitudinal reinforcement ratio on the seismic performance.

Nonlinear finite-element analysis for predicting the cyclic behavior of UHPC shear walls reinforced with FRP and steel bars

The paper presents a numerical investigation of the cyclic behavior of ultra-high-performance concrete (UHPC) shear walls with hybrid reinforcement of fiber-reinforced polymer (FRP) and steel bars. The concrete damage plasticity (CDP) model in ABAQUS was used to establish the finite-element analysis (FEA) model. The numerical results were compared to the experimental data of six UHPC shear walls in terms of damage pattern, hysteretic response, and strain distribution. The results demonstrate that the established FEA model could predict the cyclic behavior of the UHPC shear walls with an acceptable level of accuracy. A comprehensive parametric study was further conducted to investigate the influence of carbon fiber-reinforced polymer (CFRP) bars and FRP type on the cyclic behavior of UHPC shear walls. The authors suggest that CFRP bars should be used in the boundary element to improve the effectiveness of the CFRP bars. The authors suggest using a replacement ratio of CFRP bars in the boundary element of 33.3%∼66.7% to keep a balance between the self-centering and energy-dissipation capacity of the UHPC shear walls. Based on the simulation results, the UHPC shear walls with hybrid reinforcement of GFRP (glass fiber-reinforced polymer) and steel bars achieved favorable self-centering capacity while maintaining good energy-dissipation capacity.

Detection of interface flaws in Concrete-FRP composite structures using linear and nonlinear ultrasonics based techniques

Timely and appropriate retrofitting of existing structures holds paramount importance to ensure the structural integrity and sustainability. Fiber Reinforced Polymer (FRP) composites with high corrosion resistance, strength and durability, have been increasingly used in recent years for retrofitting of concrete infrastructure. The effectiveness of retrofitting is primarily dependent on the appropriate integrity at the interface between FRP and concrete substrate. Presence of any interface flaw can jeopardize the structural performance. In the present study, investigations are carried out to detect the early stage flaws at the FRP-concrete interface using ultrasonic waves. Artificial flaws of different size are introduced in the adhesive (epoxy) layer of carbon based FRP composite concrete beam. Rayleigh waves (at different frequencies) are generated for measuring the response from different FRP composite-concrete specimens. The specimens consist of three different types of materials, namely, concrete, epoxy and FRP. Two different input excitation frequencies, i.e., 75 KHz and 250 KHz, are tried out during the experimental investigations. The output signals are processed using different linear and nonlinear ultrasonic methods. Numerical simulations are also performed to better understand the wave signals’ interactions with the multi-layer composite medium. The results showed that the linear ultrasonic methods are not able to provide a consistent information on presence and extent of flaws. Nonlinear ultrasonic methods showed significantly better performance for characterizing both small and large flaws considered in this investigation. Sensitivity analysis reveals that relatively new and promising nonlinear ultrasonic technique, namely, the Sideband Peak Count-Index (SPC-I) performs remarkably well for detection of flaws in FRP-concrete interface.