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Developed to fulfil the rising societal demand for sustainable constructions, Modular Hybrid Fibre-reinforced polymer-Timber (MHFT) thin-walled sections are lightweight timber-based composite structures manufactured through a modular assembly method. Motivated by prior research on MHFT columns characterized by efficient load-carrying capacity, this paper conducted a thorough investigation into the manufacture and structural performance of MHFT beams. Experimental, analytical and numerical studies were conducted for beams subjected to four-point bending load, with parametric analyses of four distinct beam types to investigate design parameter influence on flexural performance. The experimental study demonstrated the structural efficacy of MHFT beams, as evidenced by increased moment of inertia and enhanced resistance to edge split failures, as compared to previously studied folded HFT beams. MHFT beams also exhibited a comparable strength-to-weight ratio compared to their structural steel counterparts. Both numerical and analytical methods provided acceptable predictions for flexural strength and material failure modes of MHFT beams, with strength predictions varying by less than 22% compared to experimental averages. The numerical method reliably predicted flexural stiffness and load–displacement responses, with discrepancies within 12%. The parametric analyses further revealed that the thickness of glass fibre-reinforced polymer (GFRP) layers and cross-sectional geometric profile were most strongly influenced beam parameters. Specifically, the use of 3-layer GFRP material resulted in a strength increase of over 17% and a stiffness increase of over 19% compared to 1-layer material, effectively mitigating the occurrence of local buckling and edge split failures. • New modular hybrid FRP–timber (HFT) thin-walled beams are designed and manufactured. • Experimental study reveals the manufacturing and structural efficacy of the beams. • Numerical and analytical analyses provide predictions for the flexural performance. • GFRP material has significant influence on the beam flexural strength and stiffness. [ABSTRACT FROM AUTHOR]

Hybrid FRP-timber (HFT) thin-walled sections are high-performance and lightweight wood-based composite structures, developed to meet an increasing societal demand for sustainable construction. This paper proposes an improved modular manufacturing method for HFT thin-walled sections, which inherits advantages of existing manufacturing approaches while reducing fabrication effort and significantly improving structural performance. Geometric design and fabrication processes are first demonstrated with the manufacture of structural square hollow sections. Experimental and numerical studies are then presented for stub columns loaded under uniaxial compression, with six column types investigated to demonstrate the influence of FRP and timber material selection on structural performance. The GFRP wrapping material had the most significant influence on section behaviour, with a transition from section buckling to crushing failure, and corresponding improvements in section strength and stiffness, shown with increasing GFRP layers. As compared with previously-studied folded HFT sections, modular HFT sections showed a 69% and 38% increase in strength and strength-to-weight ratio, respectively. [ABSTRACT FROM AUTHOR]