Flexural Behaviour of Corroded RC Beams Strengthened with CFRCM: Refined Modelling, Parametric Analysis, and Design Assessment

Reinforced concrete (RC) beams strengthened with carbon-fabric-reinforced cementitious matrix (CFRCM) systems have shown potential for restoring flexural performance, yet their effectiveness under different corrosion levels remains insufficiently understood. This study presents a numerical investigation of the flexural behaviour of simply supported RC beams externally strengthened with CFRCM plates. Refined finite element models (FEMs) were developed by explicitly incorporating the steel–concrete bond-slip behaviour, the carbon fabric (CF) mesh–cementitious matrix (CM) interface, and the CFRCM–concrete substrate interaction and were validated against experimental results in terms of failure modes, load–deflection responses, and flexural capacities. A parametric study was then conducted to examine the effects of CFRCM layer number, steel corrosion level, and longitudinal reinforcement ratio. The results indicate that the baseline flexural capacity can be fully restored only when the corrosion level remains below approximately 15%; beyond this threshold, none of the CFRCM configurations achieved full recovery. The influence of the reinforcement ratio was found to depend on corrosion severity, while increasing CFRCM layers enhanced flexural performance but exhibited saturation effects for thicker configurations. In addition, corrosion level and CFRCM thickness jointly influenced the failure mode. Comparisons with design predictions show that bilinear CFRCM constitutive models are conservative, whereas existing FRP-based design codes provide closer agreement with numerical and experimental results.