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[Display omitted] • A super-sensitive carbon nanofiber aggregate (SSCNFA) sensor with 0.05% CNFs content has been developed. • The sensor's sensitivity is enhanced due to a well-defined conductive path between CNFs and steel mesh. • SSCNFA can detect forces as low as 0.28 N, making it suitable for stress/strain sensing and damage detection. • The sensor has a wide dynamic range, with any frequency from 1 Hz to 500 kHz available for various applications. A carbon nanofiber aggregate of exceptional sensitivity is developed. Our approach involves the development and utilization of a novel nanobrush structure of carbon nanofiber within the mortar matrix. The high number of nanostructures in the nanobrush, particularly near the electrodes, results in a greater number of nanogaps, leading to a substantial improvement in sensitivity. We are able to detect forces as small as 1 N using this sensor. The carbon nanofiber brush (CNFB) provides a well-defined conductive path for the piezoresistive functioning of the super-sensitive carbon nanofiber aggregate (SSCNFA) with significantly reduced cost. The influence of scanning frequency in impedance is rigorously investigated with alternating current (AC) based on two methods. SSCNFAs are tested in uniaxial compression to determine the highly sensitive face of cube sensor. An SSCNFA (0.05 % CNFs, dense electrodes) and a CNFA (0.5 % CNFs, wide-spaced electrodes) were tested in a sweep-frequency test under parallel compression to compare the super-sensitive performance of the new sensor. The gauge factors at various frequencies were determined. The electrical impedance measured at various frequencies provides versatility to the SSCNFA for stress monitoring. Four fixed-frequency tests were conducted to determine the resolution under uniaxial compression and examine repeatability. [ABSTRACT FROM AUTHOR]

• Ultra-high-performance carbon nanofiber aggreagate is proposed and developed. • The relationship between electrical response and stress–strain response are obtained. • The influence of scaning frequency and loading orientation are investigated. • The proposed sensor has compressive strength of 138 MPa to fit UHPC strength. Ultra-high-performance concrete (UHPC) is rapidly implemented to build robust, durable, and sustainable structures. This study presents the development of a robust self-sensing sensor with the motivation to monitor structures with high-performance construction material, such as UHPC. The ultra-high-performance carbon nanofiber aggregates (UHPCNFAs) are carbon nanofibers (CNFs) and UHPC-based smart aggregates. The newly developed UHPCNFAs are experimentally investigated in uniaxial compression. Sweep-frequency and fixed-frequency tests are adopted in alternating current measurements for determining the electrical behavior of the UHPCNFAs. UHPCNFAs are compressed in parallel and perpendicular loading orientations to understand the difference in the sensor's electrical sensitivity and mechanical behavior in each case. In addition, the robustness of the UHPCFNA is examined to the point of failure in both orientations. The relationship between stress, strain, and electrical impedance variation is established for eight different frequencies. Furthermore, the UHPCNFAs are compressed at a fixed frequency to verify the repeatable behavior. This paper examines the effect of loading orientations on electrical and mechanical response, robustness, and sensitivity of UHPCNFA in a wide range of frequency spectrum to check its suitability in real-time structural health monitoring. [ABSTRACT FROM AUTHOR]