A Review on Research Advances and Applications of Basalt Fiber-Reinforced Polymer in the Construction Industry

Abstract

Compared to glass fiber-reinforced polymer (GFRP) and carbon fiber-reinforced polymer (CFRP), basalt fiber-reinforced polymer (BFRP) offers distinct advantages, including the relatively lower cost and superior creep resistance. As a result, its application in the construction industry has been gaining growing attention. This paper begins by providing an overview of the fundamental background, as well as the mechanical and microscopic properties, of BFs. By exploring various application types, including one-dimensional (e.g., bars, cables), two-dimensional (e.g., grids, sheets), and three-dimensional (e.g., profiles) applications, the research progress of BFRP products in the construction industry is comprehensively summarized. Research has demonstrated the effectiveness of BFRP in a variety of structural applications, such as reinforcing existing structures (e.g., concrete or masonry) using BFRP bars, grids, or sheets, and the development of novel design concepts that integrate BFRP products with existing structural systems. Furthermore, this paper identifies unresolved challenges and proposes potential research directions, intending to promote BFRP’s broader adoption as a standardized and innovative material in the construction industry.

1. Introduction

In the course of human societal development, the exploration and application of materials stand as vital substance bases and driving forces for social progress [1,2]. The discovery and utilization of each significant material signify the advancement of an era, enhancing not only humanity’s capacity to transform the natural world but also greatly elevating societal productivity and quality of life. Against the backdrop of rapid modern technological advancement, traditional single materials no longer suffice to meet complex performance requirements [3,4,5]. Consequently, global attention toward research in the field of composite materials has been escalating. The level of a country’s or region’s composite material industry has become a crucial indicator for assessing its economic and technological prowess. Generally, a composite material comprises two main components: the reinforcement material and the matrix material. While the reinforcement material does not form the continuous phase of the composite material, it predominantly serves as the carrier of its mechanical properties. On the other hand, the matrix material forms the continuous phase within the composite material and is typically a single material. Fiber-reinforced polymer (FRP), as a category of high-performance composites, is formed through the combination of two or more materials with differing properties. The fibers, serving as the reinforcement, commonly include carbon fiber (CF), glass fiber (GF), and basalt fiber (BF), among others. Currently, FRP has gradually found applications in various fields, such as construction, advanced manufacturing, new energy, low-carbon environmental protection, and military industries [6,7,8,9], as illustrated in Figure 1.

Infrastructure serves as the cornerstone of a country’s economic development, directly impacting its competitiveness and the quality of life of its citizens. Particularly in a globalized context, the construction of modern infrastructure holds significant importance for economic growth, social stability, and national security. Traditional building materials such as steel and concrete exhibit issues like poor corrosion resistance and high self-weight [10,11,12,13,14]. In comparison, fiber and its composite materials offer a light weight, high strength, excellent corrosion resistance, and fatigue resistance, making them an ideal choice for achieving long-lasting, lightweight, corrosion-resistant structures and reducing the overall life cycle costs in construction [15,16,17].

Basalt, widely present in nature, possesses stable chemical and mineral compositions. It exhibits extremely low reactivity with air and water, is non-flammable and non-toxic, and features explosion-proof characteristics. Typically characterized by high ecological compatibility and recyclability, basalt is regarded as a high-performance green inorganic material [18,19]. Not being a new material, basalt has been utilized since the Roman era for cobblestone roads and building materials. However, its innovative applications and practical value in modern industry and structural fields have brought significant convenience and progress to numerous industries.

Basalt fiber (BF), as a high-performance novel composite material reinforcement, has garnered widespread attention in recent years. It is deemed a pollution-free, recyclable, “green industrial raw material”, refs. [20,21] with energy consumption of only 1/16th of CF, priced at 1/6th of CF, exhibiting a creep rate merely 1/4th of aramid fiber (AF), and boasting superior corrosion resistance compared to GF [22]. Therefore, BF is considered a highly cost-effective fiber material in the realm of building materials. BF can maintain excellent strength and stiffness even in high-temperature environments, showcasing outstanding acid resistance, solvent resistance, low water absorption, and significant thermal and acoustic insulation properties. Furthermore, BF demonstrates good processability and relatively low production costs [18].

It is worth mentioning that BF can seamlessly integrate with various resins, such as epoxy resin, polyurethane, and phenolic resin, among others, to produce basalt fiber-reinforced polymer (BFRP). Throughout the entire production process, BFRP does not generate particulate matter (such as asbestos) that is harmful to human health. Similar to traditional FRP (carbon fiber-reinforced polymer (CFRP), glass fiber-reinforced polymer (GFRP)), BFRP finds a wide range of applications, particularly gaining increasing usage in the construction industry in recent years. BFRP, for instance, finds applications in the reinforcement and retrofitting of existing structures, such as bars, grids, and sheets; as cables in large-span bridges; as load-bearing profiles in structural components; and as insulating and soundproofing panels in buildings. The growing use of BFRP in the construction industry compels us to deepen our understanding of the mechanical properties of this material and to devise effective design methods. However, up to this point, many countries’ design standards have primarily catered to traditional composite materials (such as CFRP and GFRP), prompting extensive research efforts in that direction [18]. Consequently, the study of BFRP products and the development of corresponding design standards are indispensable.

In the research on BFRP, understanding the unique characteristics of BF is critical. Therefore, this paper first introduces the background, mechanical properties, and microscopic properties of BF. Subsequently, BFRP products are classified based on their applications, with the reviewed literature primarily focusing on studies published within the past 15 years. Various product types, including bars, cables, grids, sheets, and profiles, are examined. The research primarily encompasses the mechanical properties of the products themselves, the bond performance with concrete structures, the mechanical behavior of reinforced concrete structures, the anchoring performance of cables, and the connection performance of profile joints. Furthermore, the advancements and limitations in the application of BFRP in the construction industry are comprehensively summarized, and the future development trends in this field are outlined. The objective is to provide potential research directions for scholars in this area.

2. Basalt Fiber

2.1. Background

Basalt is a type of rock formed by the cooling of basaltic magma erupted from the Earth’s surface, which is widely distributed among all igneous rocks. From a mineralogical perspective, basalt primarily consists of plagioclase and pyroxene. In terms of its chemical composition, its main components include SiO₂, Al₂O₃, and Fe_xO_y, where the SiO₂ content is approximately 45–52%, Al₂O₃ ranges from 6 to 15%, and Fe_xO_y (the total of Fe₂O₃ and FeO) accounts for about 5–13% [23]. Currently, the basalt used for BF production requires an SiO₂ content of no less than 46%. This is because an increase in the SiO₂ content within a certain range helps improve spinning processes and enhance fiber performance [24]. Simultaneously, the Al₂O₃ content should be kept within 18% to maintain the high melt viscosity, ensuring the fiber possesses good chemical corrosion resistance. The Fe_xO_y content also has specific requirements to guarantee the thermal, crystalline, mechanical, and optical properties of the fiber [25]. Additionally, the essential addition of MgO and TiO₂ in appropriate amounts is indispensable to enhance fiber waterproofing and corrosion resistance [26].

Basalt is one of the most abundant types of rocks in the Earth’s crust [27], making BF one of the most sustainable reinforcement fibers. Furthermore, BF offers significant advantages, such as its non-toxic nature, high tensile strength, strong durability, excellent corrosion resistance, and lower production costs [18,19]. In today’s society, with an increasing awareness of ecosystem conservation and sustainable use of environmental resources, various industries are adopting or developing eco-friendly materials and processes. The construction industry, in particular, should actively promote sustainable materials with low carbon footprints. According to market forecasts [28], the market size of BF is expected to grow from USD 227 million in 2019 to USD 397 million in 2024, with a compound annual growth rate of 11.8%. Particularly in the sectors of the construction industry, there is a significant growth trend in the market demand. The increasing demand in the construction industry for non-corrosive materials is one of the key factors driving the growth in the BF demand. This not only helps with cost reduction but also effectively extends the lifespan of structures.

2.2. Comparison of GF, CF and BF

GF, CF, and BF, as common composite material reinforcements, have been widely used in the construction industry.

Table 1. Comparison of GF, CF, and BF [29,30,31].

Fiber	Density (g/cm3)	Elongation (%)	Elastic Modulus (MPa)	Tensile Strength (MPa)	Renewability	Health Risks
GF	2.5	2.5	65–72	1700–3500	No	Yes
CF	1.8	1.5–2.0	200–600	2000–5000	No	Yes
BF	1.4	3.1	80–90	2800–3100	Yes	No

summarizes the mechanical properties and sustainability characteristics of GF, CF, and BF. BF exhibits high strength, effectively meeting the design requirements of structural elements in buildings. Its lower elastic modulus can reduce the prestress losses when used as prestressed tendons in concrete structures. Additionally, BF has an elongation rate of up to 3.1%, providing structures with better ductility. Of particular note is the excellent recyclability of BF and its minimal harm to human health. Compared to other reinforcement fibers, BF demonstrates clear advantages and holds broader application prospects in various fields, particularly in the construction industry.

2.3. Microscopic Property

In recent years, BF has been widely utilized as a reinforcement material for matrices such as epoxy resin and polyurethane, enabling the production of composite materials for various applications. Since the interfacial bonding performance between BF and matrix materials plays a crucial role in determining the mechanical properties of BFRP, the analysis of its microstructure has become particularly essential and a noteworthy area of research. By applying appropriate surface treatments to the fibers, the bonding performance with the matrix can be effectively enhanced, thereby ensuring the stable transfer of loads [32]. The common surface treatment methods include fiber surface roughening [33], enhancing interactions with nanoparticles [34], chemical functionalization [35], and plasma treatment [36], as shown in Figure 2.

Halasová et al. (2019) [37] analyzed the microstructural changes in BFRP at temperatures of 650 °C and 700 °C using SEM, TEM, and spectroscopy. Fe⁰ crystals were identified within the BF, and the BCC lattice structure of the Fe⁰ particles was confirmed. Additionally, it was observed that BFRP exhibited high fracture resistance at 650 °C. However, at 700 °C, due to fiber crystallization and matrix transformations, the mechanical properties of BFRP deteriorated.

Zhao et al. (2020) [38] investigated the effects of different resin matrices on the performance of BFRP through static and fatigue tests, supplemented by in situ SEM observations. The experiments revealed that an increase in matrix ductility significantly reduced the extent of crack propagation. For BFRP with a vinyl resin matrix, the fatigue strength after 10 million cycles improved from 69.89% to 75.56% following toughening treatment.

The interfacial fracture resistance of BFRP with two different matrix materials was explored by Chlup et al. (2020) [39]. Compared to epoxy resin and cured polysiloxane matrices, the partially pyrolyzed polysiloxane matrix exhibited a fracture resistance level that was reduced by an order of magnitude. Moreover, the cured matrices demonstrated significant plastic deformation and crack-arresting capabilities.

Lilli et al. (2021) [40] modified the surface of basalt fibers (BFs) using plasma polymerization technology (PECVD), resulting in the formation of polymer films composed of tetravinyl silane or its mixture with oxygen on the fiber surface. The performance of the modified composites was evaluated through short beam shear tests, which demonstrated that the interlaminar shear strength of the modified basalt fibers increased by at least 180% compared to untreated fibers. In the same year, Lilli et al. [41] also utilized plasma-enhanced chemical vapor deposition to deposit a layer of tetravinyl silane (TVS) or its mixture on the BF surface. While the strength of the modified BF remained unchanged, the interfacial shear strength between the BF and the epoxy matrix improved by 79%, with SEM analysis confirming the strong bonding between the fibers and the matrix.

Pai et al. (2022) [42] investigated the effects of different aging conditions—environmental aging (25 °C), low-temperature aging (−10 °C), and humid aging (40 °C with 60% relative humidity)—on the mechanical properties of hybrid basalt–aramid/epoxy composites. It was revealed that low-temperature aging had the least impact on the mechanical properties, followed by humid aging, while environmental aging caused the most significant deterioration. FTIR and SEM analyses identified matrix decomposition, matrix cracking, and interfacial debonding as the primary failure mechanisms in the aged materials.

The surface of BF was modified by Zhang et al. (2024) [43] using a silane coupling agent (SCA). Analysis through SEM, FTIR, and XPS revealed the presence of hydrophilic NH₂ groups on the modified BF surface. This modification partially increased the surface roughness of the fibers and effectively protected them from erosion, thereby enhancing the interfacial bonding between the fibers and the matrix.

3. Research and Application of BFRP in the Construction Industry

To promote the application of BF and its composites in the construction industry, a series of high-performance BFRP products, such as BFRP bars, cables, grids, sheets, profiles, etc., have been developed, as illustrated in Figure 3. These products exhibit excellent mechanical properties, durability, and construction feasibility, meeting the high requirements for strength, stability, and corrosion resistance in building structures. The latest research progress related to the classification of different product types of BFRP in applications has been introduced.

3.1. One-Dimensional Level

3.1.1. Bar/Tendon

BFRP bars are recognized for their exceptional performance characteristics, including their high tensile strength, low weight, non-magnetic properties, superior corrosion resistance, enhanced fatigue resistance, and thermal expansion coefficient closely matching that of concrete. These attributes position them as a viable alternative to traditional steel reinforcement, providing a promising solution to the persistent challenge of insufficient durability in concrete structures.

Revealing the mechanical properties of BFRP bars is meaningful. In an early study by El Refai (2013) [50], static and fatigue performance tests were conducted on BF bars submerged in saltwater and alkaline solutions. It was observed that the tensile strength of the BF bars decreased by 7% and 9%, respectively, following immersion. The fatigue life of the anchorage system was primarily influenced by the stress amplitudes, with alkaline solutions found to reduce the likelihood of premature failure in the anchorage zone, exhibiting a fatigue limit of 0.04 times the ultimate load capacity. In a subsequent study by Serbescu et al. (2015) [51], tensile tests were performed under various temperature and pH conditions to collect material property data and develop an improved method for predicting the long-term strength of BF bars, as depicted in Figure 4. After 100 years of exposure to concrete and mortar environments, the residual strength of BF bars was approximately 70%. Further investigation by Lu et al. (2020) [52] involved immersing both cement mortar-coated and bare BF bars in alkaline solutions and distilled water, followed by mechanical property assessments. The alkaline environment was the primary factor contributing to the degradation of BF bars. Additionally, an alkali–aggregate reaction (AAR) was observed at the interface between the cement mortar and the BF bars, which negatively impacted the overall durability of the bars.

The bond performance of BFRP bars was studied by Dai et al. (2021) [53]. Pull-out tests were carried out to investigate the bonding properties between BFRP bars and coral reef sand concrete (CRSC). Smaller-diameter BFRP bars with short anchorage lengths were prone to pull-out failure, while larger-diameter bars with longer anchorage lengths tended to experience splitting failure. Based on existing bond-slip models, a bond-slip model suitable for BFRP bars and CRSC was proposed. The durability of carbon nanotube (CNT)-modified BFRP bars in seawater sand concrete (SWSSC) beams was examined by Su et al. (2022) [54]. The CNTs significantly enhanced the resin matrix’s fracture toughness, effectively mitigating the degradation of the tensile strength and bond strength of BFRP bars in marine environments. After a 9-month corrosion test, the bond strength of the BFRP bars remained at 87.1%. To further investigate the bonding performance between BFRP bars and reactive powder concrete (RPC), Xiao et al. (2023) [55] conducted 27 pull-out tests to explore the influence of the steel fiber volume content, protective layer thickness, and anchorage length on the bonding performance. It was revealed that there was good bonding performance between BFRP bars and RPC. Steel fiber effectively filled cracks, enhancing the bond strength, and increased the protective layer thickness, contributing to improved bond strength. Moreover, increasing the anchorage length showed an initial increase followed by a decrease in the bond strength, indicating the existence of an optimal anchorage length.

The impact of two alkaline levels of sea sand concrete (SSC) and the surface characteristics of BFRP bars (sand-coated (SC), helically wound (HWo), helically wrapped (HWr)) on the degradation at the BFRP bar and bond interface were investigated by Feng et al. (2024) [56] through shear, tension, and pull-out tests. Due to the hindrance of the sand layer, after 180 days of immersion in 55 °C seawater, the tensile strength retention of the SC-BFRP bars was 13.4% and 26.4% higher than that of the HWo-BFRP bars and HWr-BFRP bars, respectively. The bond strength of BFRP bars with low-alkalinity SSC was less affected by the environment, with over 75% bond strength remaining after 180 days. However, the bond strength of BFRP bars with normal SSC significantly decreased, with less than 50% bond strength remaining after 180 days.

The bond performance between ultra-high-performance sea sand concrete (UHP-SSC) and BFRP bars was investigated by Jiang et al. (2024) [44] to explore the effects of surface treatment methods and the anchorage length through pull-out tests. It was found that the inclusion of fibers notably enhanced the bond strength between the materials, with BFRP bars demonstrating superior reinforcement effects compared to steel fibers at identical volume fractions. The bond strength was observed to exhibit a positive correlation with the bar height and a negative correlation with the anchorage length, attributed to the nonlinear distribution of the bond stress. Additionally, a modified formula was proposed to predict the bond strength more accurately.

In a separate study, Jin et al. (2024) [57] performed numerical simulations to examine the bond performance of BFRP bars and concrete under dynamic loading conditions and elevated temperatures. The bond strength increased nonlinearly with the strain rate at various temperatures. However, at excessively high temperatures, the bond strength became largely independent of the strain rate and began to decrease progressively with the temperature rise. A semi-empirical model, which accounted for the effects of both the strain rate and temperature variations on the bond performance, was developed and validated.

Exploring the performance of components reinforced with BFRP bars was deemed crucial. Abed and Alhafiz (2019) [58] studied the influence of different types of fiber on the bending performance of concrete beams reinforced with BFRP bars. For this purpose, a four-point bending test on the beams was carried out, and the failure mode is shown in Figure 5. All the specimens first experienced concrete crushing, followed by the rupture of the BFRP bars. Compared with plain concrete beams, both BFs and synthetic fibers significantly enhanced the bending load-bearing capacity of the beams, increasing it by 12% and 19%, respectively. Additionally, BFs exhibited superior performance in terms of crack control, leading to a 21% enhancement in the cracking load of plain concrete beams.

Attia et al. (2019) [59] carried out experimental research on the bending performance of basalt fiber-reinforced concrete slabs with BFRP and GFRP bars and predicted their bending load-bearing capacity using current design standards. The cracking load of concrete incorporating BMF increased by 46% to 93%. During the tests, the slabs exhibited concrete compression failure, with no degradation observed in the FRP bars. Furthermore, the formulas in the ACI 440.1R-15 [60] and ACI 544.4R-88 [61] standards effectively predicted the bending load-bearing capacity of the slabs. The influence of basalt macro-fiber (BMF) on the shear performance of BFRP bar-reinforced concrete beams was studied by Muhammad and Yousif (2023) [62] through experiments. A substantial improvement in the shear performance of high-strength concrete beams incorporating BMF was induced, particularly in terms of the increased stiffness following the cracking of the concrete beam. Additionally, a formula for calculating the shear capacity of such beams was proposed.

Experimental research on and theoretical analysis of the eccentric compressive performance of slender BFRP bar-reinforced concrete columns were conducted by Liu et al. (2023) [63], as shown in Figure 6. No buckling or fracture of the BFRP bars was observed during the experiments, and it was found that the axial force contribution of the BFRP bars was lower than that of steel bars. An increase in eccentricity resulted in a marked decrease in the load-bearing capacity and lateral stiffness of the columns. Additionally, a formula for calculating the cross-sectional strength of BFRP bar-reinforced concrete columns was established, and the performance of existing design methods was evaluated. Mostafa et al. (2023) [64] performed four-point bending tests on BFRP bar-reinforced concrete beams, assessing the effects of the reinforcement ratio, BFRP bar dimensions, concrete strength, and bar type on the bending performance. The concrete beams reinforced with BFRP and GFRP bars exhibited a 77% higher bending load-bearing capacity than steel-reinforced concrete beams at the same reinforcement ratio, although the cracking moment was lower. The bending load-bearing capacity and mid-span deflection of the specimens were predicted using the ACI 440.1R-15 [60] standard formula, and a modified formula was proposed and validated.

To address the inadequate reinforcement effects in large-span structures and the underutilization of the mechanical properties of FRP materials, the emergence of FRP prestressed tendons became crucial, representing one of the significant means of achieving large-span and lightweight structures. The creep characteristics of BFRP prestressed tendons were identified as crucial performance indicators. Wang et al. (2014) [65] conducted experimental research on and mechanism analysis of key factors such as the creep rate and residual strength, as shown in Figure 7. There was a close correlation between the creep rate and the stress levels. Moreover, even after 1000 h of sustained loading, BFRP prestressed tendons could retain approximately 95% of their residual strength. The component performance of concrete beams externally prestressed with BFRP tendons was investigated by Wang et al. (2015) [66], as shown in Figure 8. The experimental findings showed that all the specimens exhibited concrete crushing failure. The study also indicated that utilizing epoxy resin bonding anchorage could effectively utilize the strength of BFRP tendons. Additionally, an appropriate deviation design could efficiently offset the second-order effects of the beams. Existing design methods were able to predict the reinforcement effects quite effectively.

An effective wrapping fiber plate anchorage method for testing the fatigue performance of prestressed BFRP tendons was introduced by Wang et al. (2016) [67]. The fatigue failure of BFRP tendons primarily stemmed from debonding between the outer fiber and the matrix interface, with the fatigue life being highly sensitive to the fatigue stress range. Recommended stress ranges (0.04 fu) and maximum stress (0.53 fu) for BFRP tendons were provided in the study. As shown in Figure 9, Dal Lago et al. (2017) [68] proposed a BFRP prestressed concrete slab and provided a detailed description of the associated manufacturing processes. Three-point loading tests were conducted on the slabs, and the bending performance of the slabs was predicted using nonlinear viscoelastic and elastoplastic models. The predicted results aligned with the experimental results, demonstrating good accuracy. Atutis et al. (2018) [69] investigated the stress relaxation phenomena in BFRP prestressed concrete beams and proposed a recommended stress relaxation curve that accounts for the prestress losses. The stress relaxation rate of BFRP tendons was 6.67% when the initial stress level was 55% of the ultimate strength.

Motwani et al. (2022) [70] conducted experimental research on the application of BFRP prestressed tendons in concrete beams. It revealed a prestress transfer length between 250 and 500 mm, an end slip range of 1.6–2.7 mm, and an average bonding stress ranging from 1.8 to 2.6 MPa. Ji et al. (2024) [71] applied BFRP prestressed tendons in concrete cylinder pipes and concluded through experimental research and theoretical analysis that as the bending radius increased, the degree of strength degradation of the BFRP tendons decreased, especially in large-diameter pipes where the BFRP tendons demonstrated higher cost-effectiveness.

A bending test on and numerical simulation analysis of RC beams reinforced with BFRP bars were conducted by Erfan et al. (2019) [72]. The application of BFRP bars not only increased the ductility and load-bearing capacity of the elements but also reduced the width and length of the cracks. It was noted that a brittle failure mode was exhibited by the BFRP bars when the specimens reached their ultimate load-bearing capacity. Experimental research on and numerical simulation analysis of the bending performance of BFRP bars and steel-reinforced concrete slabs were carried out by Erfan et al. (2021) [73], as shown in Figure 10. A significant improvement in the bending load-bearing capacity of BFRP bar-reinforced concrete slabs was noticed compared to steel-reinforced concrete slabs. An inverse relationship between the deflection of the slabs and the content of BFRP bars was revealed, with BFRP bar-reinforced concrete slabs exhibiting bilinear elastic behavior before failure. The bending performance of concrete beams reinforced with a combination of steel and BFRP bars through experimental and numerical simulation studies was investigated by Hussein et al. (2022) [74]. The contribution of BFRP bars to the bending capacity of the beams mainly depended on their bond strength with the concrete after steel yielding. The roughening of the surface of the BFRP bars had no significant effect on the bending performance before steel yielding. To meet the deflection limit requirements, the ratio of mixed reinforcement with BFRP bars to steel bars should be less than 1.9. Shi et al. (2022) [75,76] introduced a novel wedge anchor design for prestressed BFRP tendons. Through finite element analysis, optimization was conducted on the wedge segment length and elastic modulus. The experimental results demonstrated that the efficiency coefficient of this new anchoring system reached 91%, significantly outperforming traditional steel wedge anchors. Additionally, the fatigue life of the tendon–anchor system was found to be capable of reaching 200 million cycles when subjected to a load range of 0.05 to 0.5 times the tensile capacity.

3.1.2. Cable

Traditional steel cables are often challenged by issues such as excessive self-weight and insufficient load-bearing capacity, which render them inadequate for fulfilling the design requirements of large-span bridges. Additionally, steel cables are characterized by a limited lifespan and are prone to corrosion and fatigue damage, leading to the necessity of frequent replacements and ongoing maintenance. This not only disrupts the traffic flow but also results in substantial maintenance costs. In contrast, BFRP cables, with their lightweight nature, high strength, and extended durability, have emerged as a key solution for achieving lightweight and highly durable cable structures, offering a more dependable alternative for bridge design.

The material properties of hybrid basalt and carbon (B/C) FRP cables and various cable bridges were analyzed by Wang and Wu (2010) [77], indicating that superior mechanical performance, durability, and fatigue resistance are exhibited by B/C FRP cables compared to steel cables. Excellent mechanical properties were found by Wang et al. (2013) [78] in composites made by blending CFs or steel fibers with BFs. A significant improvement in the fatigue strength of mixed FRP composites compared to pure BFRP was shown by the experimental results. Lower and upper limits for the design of large-span cable-stayed bridges using FRP cables in terms of the strength and stiffness were proposed in the study. Yang et al. (2016) [79] conducted dynamic experiments and theoretical derivations on BFRP and CFRP cables, leading to the development and validation of a modified modal damping ratio equation. It was discovered that the CRFID model effectively captures the out-of-plane modal damping ratio. Zhou et al. (2022) [80] enhanced the compressive performance of the load transfer component (LTC) in BFRP cables by incorporating GFs and CFs. Experimental studies revealed that the optimal fiber lengths were 75, 150, and 900 μm. During testing, the primary failure modes of the LTC were identified as fiber debonding, pull-out, and fracture. A fitting formula was proposed to predict the compressive performance of the LTC, and the anchoring efficiency of the BFRP cables reached an impressive 101%.

As shown in Figure 11, the design of and experimental research on the anchoring system of high-capacity BFRP cables were conducted by Zhou et al. (2022) [45], revealing an average anchoring efficiency of 95% for BFRP cables. With increasing loads, the maximum axial strain of the BFRP cables gradually increased, while the shear stress exhibited a trend of initial increase, subsequent decrease, re-increase, and final decrease, with these two parameters, respectively, following linear and cubic function relationships. Fatigue performance tests on BFRP cables were conducted by Zhou et al. (2023) [81], considering factors such as the manufacturing processes, cable surface shapes, and anchoring methods. Ribbed cable failure was initiated by transverse cracking of the resin matrix, leading to continuous debonding at the interface. The surface shape of the cable was a key factor determining the performance of BFRP cables, while the influence of the anchoring method remains unclear.

Feng et al. (2019) [82] carried out finite element analysis of the fatigue life of CFRP, BFRP, and steel cables, proposing an appropriate method for fatigue life estimation. It was revealed that the fatigue life of CFRP cables and BFRP cables was approximately 3 times and 1.4 times that of steel cables, respectively. Furthermore, to meet the design requirement of a 100-year service life, the safety factors for CFRP, BFRP, and steel cables should not be less than 2.55, 3.27, and 3.64, respectively. Wang et al. (2020) [83] proposed a novel anchoring system for BFRP cables and conducted static tensile tests, numerical simulations, and theoretical analyses. The results demonstrated that the average anchoring efficiency of the BFRP cables reached as high as 99.2%, effectively preventing shear failure at the ends. Furthermore, the tensile strain in the middle section of the BFRP cables exhibited a linear relationship with the applied external load, and the cables showed almost no shear lag effect. The nonlinear coupled vibration characteristics of BFRP cables were investigated by Yang et al. (2023) [84] through numerical analysis. Under the same excitation, the vibration frequency of BFRP cables was found to be lower than that of steel cables, while their vibration amplitude was reduced by 44% compared to steel cables. An increase in cable tension was observed to decrease the vibration response. Moreover, the increment in the excitation amplitude was consistent with the increment in the maximum amplitude of the BFRP cables. Zhou et al. (2023) [85] developed a novel anchoring system for BFRP cables and evaluated its static performance through full-scale experiments and numerical simulations. It was demonstrated that the load transfer component (LTC) remained intact, achieving an anchoring efficiency of 93%. Additionally, it was found that using LTCs with variable stiffness effectively eliminated the stress concentration in the anchoring zone of the BFRP cables. However, current research on BFRP cables is relatively limited, both domestically and internationally, primarily focusing on other types of FRP cables [86,87,88,89,90,91,92,93,94].

3.2. Two-Dimensional Level

3.2.1. Grid

Traditional fiber cloth reinforcement techniques have certain limitations in terms of the peel resistance, fire resistance, and durability, and they are challenging to widely apply in special environments such as underwater structures and tunnels. Meanwhile, CF grids are costly, and GFs exhibit poor durability, with existing production processes being relatively inefficient. To address these issues, BFRP grids have emerged as an ideal choice combining high performance with lower costs. Ali et al. (2015) [95] conducted experimental research on the tensile properties of BFRP grids, their bond performance with concrete, and the flexural performance of reinforced steel–concrete beams. It was shown that the elastic modulus of BFRP grids ranged from 40 to 43 GPa, and the tensile strength ranged between 815 and 931 MPa. The bond performance between BFRP grids and concrete exhibited a ductile failure mode, with no instances of debonding failure in any specimens. Zheng et al. (2016) [96] combined BFRP grids with ECC for reinforcing steel–concrete beams, which is depicted in Figure 12. Through bending tests, good bond performance between the reinforcement layer and the concrete was found, with the beam primarily experiencing concrete crushing or BFRP grid fracture during loading. Finally, an analytical model was proposed to predict the beam deflection. The compressive performance of rubble walls reinforced with BFRP grids was investigated by Huang et al. (2018) [97] through experimental testing. It was shown that the load-bearing capacity of the walls could be increased by up to 2.5 times with BFRP grid reinforcement, while the out-of-plane displacement was significantly reduced.

Dong et al. (2021) [98] used BFRP grids as shear reinforcement for a new type of seawater–sea sand concrete beams (SWSSC) and conducted four-point bending tests. A significant improvement in the bending stiffness when using BFRP grids was noticed, with smaller crack widths. Wen and Wan [99] carried out shear fatigue tests on the interface between BFRP grids and concrete, analyzing the fatigue failure modes and proposing a theoretical model of bond-slip fatigue degradation based on the experimental results. Uniaxial tensile tests on high-ductility fiber-reinforced concrete embedded with BFRP grids were conducted by Zhang et al. (2022) [100]. The tensile capacity of concrete was significantly enhanced by BFRP grids. Based on the experimental results, corresponding formulas for calculating the ultimate tensile strength capacity were proposed. He et al. (2024) [101] conducted experimental research on the fatigue performance of BFRP grid-reinforced steel–concrete beams. The beam’s fatigue life was significantly extended by the BFRP grids, with the effect being more pronounced when using prestressed BFRP grids. Additionally, the bond performance between BFRP grids and concrete was good and reliable. Finally, a fatigue life prediction model was proposed.

Bending tests on tailings sand ultra-high ductile concrete beams reinforced with BFRP grids were carried out by Song et al. (2024) [102]. It was noticed that there was a significant improvement in the bending load-bearing capacity of the beams due to the BFRP grids. Based on existing formulas, the research team further derived the corresponding formulas for the bending load-bearing capacity. The shear performance of steel–concrete beams reinforced with prestressed BFRP grids was investigated and a shear capacity calculation formula was derived by Zhou et al. (2024) [46]. The shear performance of steel–concrete beams reinforced with BFRP grids was revealed by Zhou et al. (2025) [103] through experimental research. A significant improvement in the initial stiffness and bending load-bearing capacity of the reinforced beams was found. Moreover, the ACI 549.4R-13 [104] standard was suitable for predicting the contribution of BFRP grids to the shear load-bearing capacity of beams.

Zheng et al. (2020) [105] reinforced RC beams using BFRP grids and engineered cementitious composites (ECCs), uncovering the changes in the shear performance before and after reinforcement. The bond between the BFRP grid and the concrete was strong, effectively suppressing diagonal cracks in the beams. Based on the finite element simulation results, a corresponding formula for calculating the shear load-carrying capacity was proposed. Zhang et al. (2023) [106] investigated the flexural performance of corroded RC beams reinforced with BFRP grids and ECC. Through a combination of experimental testing and numerical simulation, it was found that the tensile stress in the BFRP grid at failure was only 50–70% of its ultimate tensile strength. Furthermore, a theoretical model to predict the moment values at critical points was successfully developed.

3.2.2. Sheet/Strip

Due to their excellent corrosion resistance, substantial lightweight advantages, and good processability, BFRPs are deemed suitable for various construction and repair projects. Their environmental friendliness and durability make them stand out in harsh environments, where the structural self-weight can be effectively reduced. In recent years, significant interest in BFRP sheets has been shown by scholars.

As presented in Figure 13, experimental research was conducted by Zhou et al. (2013) [107] using BFRP sheets to reinforce unreinforced masonry walls, followed by detailed testing of their in-plane seismic performance. The enhancement effect of BFRP reinforcement on the seismic performance of unreinforced masonry walls was evaluated, and the corresponding design models were proposed based on the results. Earthquake-damaged reinforced concrete circular bridge columns were repaired by Jiang et al. (2016) [108] using BFRP sheets, as depicted in Figure 14, followed by cyclic tests under lateral loads. A significant increase in the flexural load-bearing capacity of the repaired columns was induced, with some restoration of ductility achieved. A study conducted by Qin et al. (2019) [109] revealed that after reinforcing cracked concrete beams with BFRP sheets, there was a significant increase in both the flexural stiffness and the load-bearing capacity. The beam failed because the concrete in the compression zone was crushed. Additionally, it was noted that increasing the number of BFRP sheets helped further enhance the flexural load-bearing capacity, albeit with certain limitations in terms of the improvement.

To study the dynamic bond strength between BFRP sheets and steel fiber-reinforced concrete (SFRC), shear tests were carried out by Yuan et al. (2019) [110]. The bond strength and bond slip were highly sensitive to the loading rates, with the failure mode transitioning from concrete matrix failure to interface failure with increasing loading rates. A bond-slip model considering the influence of the loading rates was established based on the experimental data. As illustrated in Figure 15, Pham et al. (2020) [111] investigated the impact performance of BFRP sheet-reinforced lightweight rubberized concrete beams. Rubberized concrete beams slowed down the stress wave velocity and exhibited reduced displacement and peak impact force. A novel epoxy anchor rod for enhancing the bond performance between BFRP sheets and reinforced concrete beams was proposed by Yuan et al. (2021) [47].

As shown in Figure 16, the repair of modified reinforced concrete beam–column joints with BFRP sheets was carried out by Shen et al. [112], followed by a study on their seismic performance. The joints’ seismic performance was effectively improved by the BFRP sheets, leading to a delay in concrete spalling and enhancement of the bond performance between the steel reinforcement and the concrete. Reinforced concrete columns with BFRP sheets were strengthened by Zeng et al. (2022) [113], followed by lateral push and seismic tests. It was determined that externally bonded BFRP improved the strength, ductility, and energy dissipation capacity while also enhancing the recoverability.

The interface bond performance and flexural strength of steel-reinforced concrete beams strengthened with BFRP sheets were studied by He et al. (2023) [114,115]. The maximum stress at the interface occurred at the end of the bonding region, primarily resulting in debonding failure at that location. Additionally, after reinforcement with BFRP sheets, the flexural load-bearing capacity of the steel-reinforced concrete beams increased by 78.56%. It was suggested that BFRP sheets should be applied for reinforcement before the load-bearing capacity of the steel-reinforced concrete beams reaches 90% to enhance their repairability. Evaluation of the bending failure process of steel-reinforced concrete beams reinforced with BFRP sheets was conducted by Liu et al. [116] using non-destructive testing techniques, studying the damage process and failure mechanisms. Kang et al. [117] found through experimental research that when damaged high-performance concrete (HPC) composite beams were reinforced with BFRP sheets and subjected to secondary chloride corrosion, most specimens exhibited the failure mode of BFRP sheet peeling. However, with an increase in the number of BFRP sheets, the cracking load and flexural load-bearing capacity of the specimens increased by 27.9% and 35.8%, respectively.

Bending tests on concrete T-beams reinforced with BFRP sheets were conducted by Nayak et al. [118], demonstrating that the BFRP sheets effectively increased the bending load-bearing capacity and reduced the deflection. When the BFRP plates are installed at a 45-degree angle, the reinforcement effectiveness surpassed that achieved with a 90-degree installation or in the absence of BFRP plates altogether. Based on the experimental result, a refined finite element model was established and validated.

3.3. Three-Dimensional Level

FRP profiles, with their excellent properties, such as the light weight, high strength, and corrosion resistance, have unmatched advantages in reducing the structural self-weight, enhancing construction convenience, and improving the structural durability compared to other FRP products. Currently, there is more research on CFRP profiles and GFRP profiles [119,120,121,122,123,124]. GFRP profiles, with their lower cost advantage, have gained a certain market share compared to CFRP profiles. However, GFRP profiles face issues such as the lower creep fracture stress, higher creep rate, and significant long-term deformation. BFRP profiles, while ensuring a higher cost–performance ratio, have successfully overcome the drawbacks of GFRP, better meeting the demands of the construction industry for lightweight, large-span, and highly corrosion-resistant structures.

Lu et al. (2014) [125,126,127] studied the water absorption and mechanical property changes of pultruded BFRP sheets after thermal aging, as well as the impact of continuous loading and high-temperature environments on the mechanical performance, proposing relevant recommendations. As presented in Figure 17, the axial compression and axial tensile mechanical properties of pultruded BFRP round tubes were revealed by Ding et al. (2018) [48], with an analysis of the influence of the slenderness ratio on the failure mode and the derivation and verification of a stable load-bearing capacity calculation formula. Experimental research on the tensile performance changes of BFRP profiles in acidic environments was carried out by Wang et al. (2018) [128]. BFRP profiles have excellent durability, with almost no change in the tensile modulus and only an 18.4% decrease in the strength. A strength degradation model was established considering the temperature and pH values. The impact of BFRP bolts, stainless steel bolts, and hybrid steel–FRP bolts on the static and fatigue performance of pultruded sheets was studied by Abdelkerim et al. (2019) [49]. HSFRP bolts outperformed the other types significantly, exhibiting ductile failure. The specimens maintained their rigidity throughout the entire fatigue life, and under the same fatigue load range, BFRP bolts could replace SS bolts.

The impact of different connecting materials on the static and fatigue performance of pultruded BFRP bolt connections was revealed by Ding et al. (2021) [129] through experiments. All the bolt connections experienced shear failure, independent of the connecting material. Nodes composed of BFRP bolts and BFRP cover plates exhibited better fatigue performance than steel bolt-connected nodes. Stability analysis of pultruded BFRP circular and rectangular tubes, including fitting relevant stable load-bearing capacity calculation formulas based on the experimental results, was conducted by Chen and Zhang (2024) [130] and the on-site test is shown in Figure 18. The tensile performance of pultruded BFRP sheets under multi-bolt connections was studied by Liang et al. (2024) [131,132]. The nodes exhibited brittle shear failure when the end-to-diameter ratio and pitch-to-diameter were small, while they displayed ductile pin-bearing compressive failure when the end-to-diameter ratio was not less than 4 and pitch-to-diameter was not less than 4.5. Ultimately, the study provided a formula for calculating the ultimate load-bearing capacity of the bolt connections in BFRP sheets.

Liu et al. (2020) [133] proposed a bolt connection form for FRP profiles, conducted experimental research on different BFRP ply angles and sequences, and combined numerical simulations to analyze the failure process of nodes. The optimal arrangement and proportion of 0-degree, 45-degree, and 90-degree ply layers were derived, noting that the Hashin–Rotem failure criterion was not entirely applicable.

4. Discussion

A comprehensive review of the research on BFRP products in the construction industry over the past 15 years has been conducted. These studies are categorized based on the different application types, primarily including the mechanical properties of BFRP products themselves, the bond performance between BFRP products and concrete structures, the mechanical behavior of reinforced concrete structures, the anchoring performance of cables, and the connection performance of profile joints. The distribution of the relevant literature is shown in Figure 19.

4.1. One-Dimensional Level

4.1.1. Bar/Tendon

BFRP bars exhibit exceptional durability in saline solutions and alkaline environments, and under high-temperature conditions, particularly in marine engineering, humid and hot environments, and alkaline concrete, where their mechanical property retention is relatively high. At the same time, they significantly improve the structural ductility, flexural capacity, and crack control ability. However, alkaline environments can induce alkali–aggregate reactions (AARs) at the interface, adversely affecting the durability. The bond performance between BFRP bars and concrete is excellent, with notable effectiveness in ordinary concrete, ultra-high-performance concrete (UHP-SSC), and sea sand concrete (SSC) used in special environments. The bond performance is significantly influenced by the surface treatments (such as sand coating), anchorage length, and cover thickness, with optimization of the design further enhancing the bond strength.

To address the inherent brittleness of BFRP bars, modification measures such as the incorporation of carbon nanotubes (CNTs) and steel fibers have been investigated, resulting in improved toughness and interfacial strength, while also delaying corrosion and degradation. Under flexural, shear, and eccentric compressive conditions, structures reinforced with BFRP bars demonstrate superior bending and shear performance, surpassing that of reinforced concrete structures. However, brittle failure limits their application in scenarios requiring high ductility.

As a significant development direction, BFRP tendons have played an important role in long-span and lightweight structures. Research on their creep performance and fatigue life has shown that high residual strength is maintained even under long-term loads, while the development of novel wedge-shaped anchorage designs has significantly enhanced the anchorage efficiency and reliability.

4.1.2. Cable

BFRP cables, owing to their light weight, high strength, corrosion resistance, and fatigue resistance, have emerged as a critical technological approach in long-span bridge design. Compared to traditional steel cables, they significantly reduce the self-weight while enhancing the durability. Studies have demonstrated that hybrid FRP cables, composed of basalt fibers combined with carbon fibers or steel fibers, exhibit superior mechanical properties and fatigue strength compared to pure BFRP cables. Furthermore, an optimized anchoring system can achieve an anchoring efficiency of up to 95%, maintaining stable deformation under long-term cyclic loading and enduring over two million fatigue cycles. The surface morphology of the cables (e.g., ribbed cables) has been shown to significantly influence the interfacial bonding performance and fatigue lifespan. Transverse cracking and interfacial debonding are regarded as the primary modes of fatigue failure.

Compared to steel, BFRP cables exhibit superior fatigue resistance, reduced vibration amplitudes, and a safety factor that guarantees a service life of 100 years. Despite advancements in anchoring systems, load transfer components, and dynamic performance, the current research remains limited, primarily focusing on other types of FRP materials. This highlights the need for further exploration of BFRP cables in practical applications.

4.2. Two-Dimensional Level

4.2.1. Grid

Studies have indicated that the tensile strength of BFRP grids can reach 815–931 MPa, with an elastic modulus ranging between 40 and 43 GPa. The interface between the BFRP grid and the concrete exhibits a ductile failure mode, without significant debonding, thereby significantly enhancing the flexural, shear, and fatigue performance of the concrete components. When applied to the reinforcement of reinforced concrete beams, BFRP grids not only improve the initial stiffness and flexural capacity of the components but also markedly extend the fatigue life of the beams. The use of prestressed BFRP grids has been shown to yield even more pronounced effects. Furthermore, it has been observed that concrete components reinforced with BFRP grids primarily fail due to concrete crushing or grid rupture during the loading process. A bond-slip degradation model and load-bearing capacity calculation formula, proposed based on experimental results, provide theoretical support for engineering applications.

In specific applications, the combination of BFRP grids with novel concrete materials—such as ECCs (engineered cementitious composites), high-ductility fiber-reinforced concrete, and ultra-high-toughness tailings sand concrete—has been demonstrated to further enhance the overall tensile capacity, flexural stiffness, and crack control capabilities, offering reliable solutions for reinforcement design in complex environments. In seawater–sea sand concrete beams (SWSSC), the use of BFRP grids as stirrups has been found to significantly improve the flexural stiffness and durability of the beams. Additionally, research has revealed the failure modes in shear fatigue and shear resistance, demonstrating that the shear capacity of BFRP grids is significantly superior to that of traditional reinforcement materials. The applicability of the ACI 549.4R [104] guidelines in predicting the contribution of BFRP grids to shear resistance in components has also been validated.

4.2.2. Sheet/Strip

In specific applications, the reinforcement of unreinforced masonry walls with BFRP sheets has been found to significantly improve their in-plane seismic performance. When applied to the repair of earthquake-damaged bridge piers, BFRP sheets have demonstrated a remarkable enhancement of the flexural capacity and ductility. For cracked concrete beams, the use of BFRP sheets effectively improves the flexural capacity and stiffness, although the extent of the improvement is limited by the number of sheet layers applied. Additionally, dynamic bond tests have revealed that the bonding performance between BFRP sheets and concrete is highly sensitive to the loading rates, with higher loading rates being more likely to result in interfacial failure rather than the failure of the concrete substrate. By introducing innovative epoxy anchoring techniques and optimizing the laying angles (e.g., 45° orientation), the bonding performance and flexural effectiveness of BFRP sheets have been further enhanced.

The application of BFRP sheets in complex structures and specialized materials has also shown promising results. For instance, the impact performance of lightweight rubberized concrete beams has been improved, with BFRP sheets shown to mitigate the stress wave propagation and peak impact forces, thereby significantly enhancing the impact resistance of the structure. In high-performance concrete composite beams subjected to chloride corrosion, the use of BFRP sheets effectively increased the cracking loads and flexural capacity, although multi-layer BFRP sheet reinforcement may lead to a peeling failure mode. Tests on the lateral loading and seismic performance of reinforced concrete columns have demonstrated that externally bonded BFRP sheets significantly improve the strength, ductility, and energy dissipation capacity, while also enhancing the recoverability of the columns to some extent.

Moreover, experimental results have indicated that the flexural capacity of reinforced concrete beams strengthened with BFRP sheets can be increased by up to 78.56%, with interfacial debonding failure typically occurring at the ends of the bonded region. Consequently, it is recommended that BFRP sheets be applied to beams before they reach 90% of their load-bearing capacity to enhance their reparability. The monitoring and damage assessment of flexural failure processes using non-destructive testing techniques has further revealed the underlying failure mechanisms, providing critical insights for practical engineering applications.

4.3. Three-Dimensional Level

BFRP profiles have demonstrated exceptional durability in complex environments. For instance, in acidic conditions, the tensile elastic modulus remains almost unaffected, while the strength decreases by only 18.4%. The long-term performance can be evaluated through the establishment of strength degradation models. The mechanical properties of BFRP profiles vary depending on factors such as the cross-sectional shape, slenderness ratio, ply design, and connection method. For example, in pultruded circular and rectangular tubes, the compressive strength and buckling capacity are significantly influenced by the slenderness ratio, and relevant calculation formulas have been derived.

In terms of the structural connections, the bolted connection performance of BFRP profiles is a key area of research. Experiments have shown that appropriate end distances and bolt spacing can significantly enhance the joint performance and prevent brittle failure. Furthermore, BFRP bolted connections exhibit superior fatigue performance compared to steel bolted joints, with higher ductility and stiffness observed. Additionally, studies on the connections of BFRP profiles under various environmental and complex loading conditions, including optimized designs for different ply angles and stacking sequences, have significantly improved the overall load-bearing performance.

4.4. Limitations of Current Research

Although BFRP products have garnered widespread attention in the construction industry due to their excellent properties, such as the high strength, light weight, corrosion resistance, and eco-friendliness, the current research still faces limitations in certain aspects. These limitations are primarily manifested in the incompleteness of design codes, insufficient studies on long-term performance, and lack of research on extreme environmental adaptability.

Currently, the application of BFRP in actual engineering lacks comprehensive design theories and codes. Standardization efforts in terms of the strength design, deformation design, fatigue life design, and fire resistance design are still at the stage of improvement. Moreover, most existing design codes are based on traditional materials such as CFRP and GFRP, failing to fully consider the uniqueness of BFRP in terms of the mechanical properties, durability, and construction techniques, thereby limiting its application in complex engineering projects to a certain extent.

Despite the superior corrosion resistance and fatigue performance of BFRP, systematic studies on its performance degradation under long-term service conditions (such as high-temperature, high-humidity, and alkaline environments) have not been conducted. For instance, in marine environments, the degradation of the bond strength between BFRP and the mortar interface and the impact of alkali–aggregate reactions still require further exploration. Additionally, there is a lack of sufficient data support for the changes in mechanical properties of BFRP exposed to extreme environments (such as salt spray, ultraviolet radiation, and high temperature), thus limiting its use in high-demand environments to some extent.

There is limited research on the mechanical behavior of BFRP products under extreme loads (such as impact loads and fires), particularly in critical applications like bridge cables and prefabricated components. This uncertainty in performance significantly affects the safety and reliability of engineering design. Furthermore, there is insufficient experimental and numerical analysis data to support the structural response characteristics of BFRP under complex dynamic actions such as earthquakes and wind loads, further restricting its widespread application in special environments.

5. Conclusions

This paper aims to categorize the applications of BFRP in the construction industry. On that basis, the advances and limitations in terms of the research of BFRP products are summarized in detail. The major conclusions and outlook of this study are listed in the following.

BF, derived from natural basalt rock, possesses significant advantages compared to traditional fiber materials such as CF and GF, including being non-toxic, exhibiting high tensile strength, exceptional durability, and outstanding corrosion resistance, and having lower production costs. Additionally, the production and utilization of BF are environmentally friendly, which has led to its widespread application in fields such as the construction industry. To enhance the interfacial bonding performance between BF and the matrix, effective strategies include fiber surface roughening, strengthening interactions with nanoparticles, chemical functionalization, and plasma treatment.

This characteristic holds substantial value, as BF can be combined with resins such as epoxy or polyurethane to produce BFRP. This innovative composite material has garnered extensive attention from researchers. In the field of the construction industry, BFRP products are categorized by their application types into three groups: one-dimensional (e.g., bars, cables), two-dimensional (e.g., grids, sheets), and three-dimensional (e.g., profiles) applications. In recent years, research findings related to BFRP have been extensively summarized and explored, focusing primarily on the mechanical properties of BFRP products, the bonding performance between BFRP bars, grids, or sheets and concrete structures, the mechanical behavior of concrete structures strengthened with BFRP, the anchoring performance of BFRP cables, and the connection performance of BFRP profile joints.

The existing design methods and standards are often not fully applicable or precise when accounting for BFRP. While the research on various applications of BFRP has been extensive, there is still a lack of comprehensive design methods for the component strength, deformation, fatigue life, fire resistance, and other aspects. The design standards are worthy of improvement. Future studies could integrate machine learning techniques to further investigate these domains, leveraging data-driven analysis and optimization to enhance the accuracy and efficiency of related design systems. Moreover, integrating sensing technology with BFRP products to obtain real-time data on the stress, strain, and environmental effects would enhance the maintenance strategies, improve safety, and extend the service life of structures. Innovative applications, such as BFRP prestressed modular structures and full BFRP profile systems, could revolutionize construction, especially in large-scale infrastructure projects. Combining BFRP with advanced techniques like 3D printing could also lead to lightweight and durable structures with complex designs.

It was valuable to explore BFRP’s long-term performance in harsh environments, including high humidity, alkalinity, extreme temperatures, and UV exposure, to better predict its durability. Additionally, studies on its adaptability to extreme conditions, such as fire, seismic loads, and impact forces, are essential for expanding its use in critical infrastructure. Developing hybrid systems that combine BFRP with materials like CFRP or steel fibers could further enhance its mechanical properties. Furthermore, exploring eco-friendly resins, recycling methods, and life cycle sustainability will help reduce costs and make BFRP a more environmentally friendly alternative.