Premature debonding between carbon fiber-reinforced polymer (CFRP) and concrete is a critical issue in structural reinforcement applications, often leading to a significant reduction in the load-carrying capacity of the system. This failure mode is typically initiated by inadequate adhesion at the interface, compromising the effectiveness of CFRP in enhancing the structural performance of concrete elements. To address these issues, this study explores the impact of silica sand on the mechanical and adhesion properties of epoxy resin composites. Initially, this paper investigates the physical and mechanical properties of epoxy resin composites by varying the ratios of silica sand from 0% to 15% by volume. Subsequently, it examines the effectiveness of these composites as sealing materials to enhance the bond strength between CFRP and concrete. Incorporating a 10% silica content improves the mechanical properties of the epoxy resin, with the tensile strength increasing from 29.47 MPa to 35.52 MPa and an elastic modulus from 4.38 GPa to 5.83 GPa. Furthermore, silica sand enhances the adhesion strength between CFRP and concrete, as confirmed by the increase in the pull-out force from 14.21 kN to 18.79 kN. Silica particles improve surface roughness and interlocking, contributing to a better load distribution and stress transfer at the interface. Therefore, silica-filled epoxy resin is an efficient material for CFRP–concrete bonding applications.

Experimental tests on confined concrete specimens are essential to characterize the mechanisms activated under varying degrees of confinement. Such characterization is critical for understanding how full, partial, and non-uniform wrapping configurations influence strength and ductility enhancements. This study investigates the compressive behavior of concrete cylinders (160 mm × 320 mm) confined using full, partial, and non-uniform carbon fiber-reinforced polymers (CFRP) configurations. In the first phase, all wrapping schemes were applied with equivalent quantities of CFRP, enabling a direct performance comparison under material parity. The results indicate that non-uniform confinement (NUC) achieved approximately 15% higher axial strength than full confinement (FC2) using the same amount of CFRP. In the second phase, the NUC configuration was tested with 25% less CFRP material, yet the reduction in strength was limited to about 3%, demonstrating its superior efficiency. A new predictive model was developed to estimate peak axial stress and strain in CFRP-confined concrete cylinders. Compared to existing models, the proposed model demonstrated greater predictive accuracy (R² = 0.98 for stress and 0.91 for strain) and reduced error metrics (RMSE and scatter index). ANOVA confirmed the statistical significance of the model’s predictions (p < 0.00001 for stress, p = 0.002 for strain). These findings highlight the performance advantages and material efficiency of non-uniform CFRP confinement and support the utility of the proposed model as a practical design tool for developing advanced confinement strategies in structural engineering.