Carbon Black Nanoparticle-PP Fiber Interfacial Engineering for Piezoresistive Self-Sensing Cementitious Nanocomposites.

Carbon black (CB) nanoparticles (~20 nm) offer high specific surface area and conductivity for self-sensing cementitious composites, but strong interparticle van der Waals forces drive agglomeration in alkaline pore solutions, limiting sensing reliability. This study introduces a nanoscale interfacial engineering strategy in which CB nanoparticles are adsorbed onto polypropylene (PP) fiber surfaces as spatially organized conductive elements, with EDS evidence of enhanced hydrate coverage at the fiber-matrix interface. Three CB dosages (0.5%, 1.0%, and 1.5% by binder mass) with 0.5% PP fiber were investigated. Nanoparticle coating and interfacial micro-structure were characterized by SEM-EDS, while FTIR was used to verify that the fiber backbone remained chemically unmodified; piezoresistive response and durability were assessed via cyclic compression, DIC, and hygrothermal cycling. The 1.0% CB nanocomposite lies within the effective percolation window (~0.9-1.2%), showing high linearity, a stable gauge factor (~100), and distinct FCR acceleration for early-warning sensing. The 1.5% CB composite yields higher sensitivity but scattered responses due to nanoparticle clustering; 0.5% CB remains below the percolation threshold with a discontinuous network. After 60 hygrothermal cycles, the 1.0% nanocomposite retains >93% of its gauge factor with minimal resistance drift. The nano-engineered CB-PP fiber architecture offers a scalable route integrating crack bridging, percolation networking, and durable self-sensing in cementitious nanocomposites for structural health monitoring.