1. Introduction
Red beds are widely distributed across China and tend to exhibit progressive disintegration [
1,
2,
3], i.e., the disintegration of a rock mass in contact with water does not occur immediately but rather gradually over time through cycles of wet and dry conditions until it reaches its smallest particle size. Such gradual disintegration indicates long-term variability, which is challenging in stabilizing in aqueous environments. Consequently, red-bedded soft rocks are not easily utilized as foundations, fill materials, or raw materials for building material manufacturing. As a result, engineering construction in red-bedded areas can be expensive, and waste reuse is difficult, necessitating further research [
4,
5,
6].
Similar materials are often employed in indoor experiments to facilitate research in rock science and engineering. Developing similar materials that can simulate the progressive disintegration characteristics of red-bedded soft rocks advances the study of the interaction between rocks and water with sensitive hydrological properties and promotes the use of soft rocks in the red layer.
The majority of current studies focusing on rock-like materials employ barite powder [
7,
8,
9], sand [
9,
10,
11,
12], and iron powder [
9,
11] as primary aggregates. Gypsum [
9,
10,
11,
12], clay minerals [
7,
10], cement [
10,
11], and rosin alcohol solution [
9,
12] are commonly utilized as binding materials, with aggregates and binders combined to prepare rock-like materials. Alterations in the type, gradation, and strength of these aggregates and binding materials facilitate the preparation of materials with diverse analogous ratios to natural rocks, as determined through physical and mechanical parameters, such as the strength, elastic modulus, and density. To address the issue of producing materials with analogous hydrological characteristics, X.D. et al. [
13] used bentonite, quartz sand, barite powder, rosin alcohol solution, and gypsum as source materials to prepare similar materials for swelling rocks. They then analyzed the disintegration behavior of these materials with varying ratios as they absorbed water and swelled. C.Z. et al. [
14] created a material to imitate the eventual disintegration of soft rock, achieved by employing natural red-bed soft rock powder as the aggregate, sodium silicate as the cementing agent, and sodium dihydrogen phosphate as the curing agent. To date, none of the aforementioned studies have successfully prepared similar materials that can realistically replicate the gradual disintegration behavior exhibited by soft rocks because the strength and hydrological properties of these materials are entirely dependent on the cementing material. When the cementing material is insoluble in water, the resulting material exhibits no disintegration characteristics when immersed. Conversely, when the cementing material is soluble in water, similar materials disintegrate immediately upon immersion and cannot replicate the gradual disintegration behaviors observed in red-bedded soft rocks within a water environment, thus highlighting the significant challenge in generating comparable materials with progressive disintegration characteristics solely using binder materials and underscoring the need for new and innovative approaches.
Red-bedded soft rock is a type of sedimentary rock that forms gradually over an extended period of geological history. While the temperature and pressure conditions during their formation are not sufficiently high to cause metamorphism, the sediment particles are subjected to geological processes such as edge-breaking and recrystallization under prolonged stratigraphic pressure. As a result, sediment particles undergo tightly embedded solidification [
15,
16,
17]. Therefore, the strength of natural soft rocks is not solely derived from the binding action of the cementing material but also from the embedded solidification between the particles themselves. This embedded solidification does not disintegrate immediately upon contact with water during soft rock immersion but instead requires several dry–wet cycles before it gradually loosens and eventually disintegrates. To prepare similar materials with progressive disintegration, it may be possible to simulate the partial diagenesis of soft rocks during their geological history and promote particle embedding within comparable materials.
This study aims to explore a technical approach for preparing similar materials with progressive disintegration characteristics that mimic red-bedded soft rock by analyzing their disintegration mechanisms. To achieve this goal, first, the mechanism of progressive disintegration and cementation formation in red-bedded soft rock is investigated. Subsequently, a suitable method is explored to hasten the development of embedded solidification between aggregates and develop corresponding sample preparation devices to prepare specimens under temperature and pressure conditions that simulate sedimentary rock aggregates without significant metamorphism and prepare similar materials with strong embedded solidification to simulate the progressive disintegration behavior of red-bedded soft rocks. The production of such materials and devices will provide valuable technical support for developing indoor model experiments to study the progressive disintegration characteristics of red-bedded soft rock.
2. Mechanisms of the Progressive Disintegration of Red-Bedded Soft Rock
In this study, the microstructural electron microscopy (SEM) results of a natural red-bedded soft rock sample (muddy siltstone) from Guang’an, Sichuan are shown in
Figure 1, the basic physical and mechanical properties of the rock sample are shown in
Table 1, the mineralogical composition of the XRD test is shown in
Table 2, and the results of the particle size analysis are shown in
Table 3.
As shown in
Figure 1: the primary mineral quartz sand particles in the rock are closely arranged, form an embedded solidification between the particles, and are closely wrapped by clay minerals. A large amount of microporosity is also visible in the natural rock samples, and the microporosity can absorb water after drying. The compositional analysis in
Table 2 shows that the cement in the rocks is mainly muddy cement, which absorbs water, swells, and loses strength easily.
Previous studies have identified three principal causes of red-bedded soft rock disintegration [
18,
19,
20,
21]:
- 1.
Cement dissolution resulting in the detachment of solid particles.
- 2.
Non-uniform solid particle expansion due to water absorption after immersion.
- 3.
Pneumatic cracking of soft rocks occurs as water enters the pores of the rock and compresses the air in the sealed pores after immersion.
The mechanisms and processes of these three modes of disintegration are not identical:
- 4.
Cement dissolution, which undermines the mineral cementation of the rock, progresses more rapidly, and remains dissolved as long as the solution does not reach the saturation state of the corresponding ion. Thus, adequate water immersion does not lead to progressive disintegration via cement dissolution.
- 5.
Non-uniform swelling of particles by immersion in water disrupts cementation and mineral particle bonding; however, a single non-uniform swelling event only slightly opens the cementation; therefore, multiple iterations of non-uniform swelling are required for cracking to occur, necessitating repeated dry soaking to break tightly cemented bonds.
- 6.
Gas-induced collapse, illustrated in
Figure 2, is the primary contributor to red-bedded soft rock disintegration.
The disintegration process of soft rock, as depicted in
Figure 2, can be described as follows. After a soft rock containing micropores is dried and immersed in water, the pore water penetrates deep into the pores of the rock under capillary forces (surface tension). The original air in the pores is compressed, resulting in a decrease in volume from V
1 to V
2 and an increase in pore pressure from P
1 to P
2, causing pores with a crack strength less than P
2 to expand and mineral particles to loosen. As the pores continue to expand, the volume of available air increases, leading to a decrease in the air pressure and ultimately stopping the expansion process. This cycle is repeated in the subsequent drying and leaching stages, resulting in the progressive disintegration of the rock from particle loosening to unraveling.
The strength of red-bedded soft rock arises from two primary factors:
- 7.
Cementation between mineral grains.
- 8.
Embedded solidification. The disintegration of clay cement is the primary cause of soft rock disintegration. However, the disintegration of many red-bed soft rocks does not occur instantaneously; instead, it occurs progressively with dry–wet cycles, resulting in progressive disintegration.
Therefore, embedded solidification in red-bedded soft rock is the primary reason for progressive disintegration upon water immersion. Previous studies used different cements to prepare similar materials, which can only impart cementing strength but not embedded strength. Consequently, the resulting materials either disintegrate immediately or do not disintegrate, failing to reflect the progressive nature of disintegration.
The primary challenge is the inability to simulate long geological time scales under laboratory conditions. Therefore, it is necessary to accelerate the rheology and recrystallization of similar particles to mimic the pressure-soluble and growing effects of the particle edges in natural rocks. Through extensive exploratory experiments, ultra-low-temperature silica–titanium transparent glass powder (STGP) was identified as an effective material. STGP is an inorganic, fixed, hard particle composed of SiO2, TiO2, and other materials that melts and crystallizes at high temperatures. STGP is chemically stable and begins to melt at 450 °C. In this study, STGP was mixed with quartz sand aggregate (with a melting point of 1000 °C). Upon heating above 450 °C, STGP gradually fuses and attaches to the surface of the quartz sand aggregate, increasing its volume and allowing the angles of the particles to grow into the pores, prompting the formation of an embedded solidification between the aggregate particles.
3. Sample Preparation
3.1. Sample Materials and Sample Preparation Systems
The careful selection of materials is necessary to ensure similarity between similar specimens and natural rock samples in terms of basic physical and mechanical properties as well as disintegration properties. When considering the three mechanisms of disintegration and the destruction of red-bedded soft rocks, the materials chosen must adhere to the following principles: first, they should possess the fundamental characteristics of soft rocks; second, they should partially dissolve in water; third, they should exhibit a certain degree of water absorption and swelling characteristics; fourth, they should be capable of resisting water inlay and gradually deteriorate under multiple dry–wet cycles.
Considering the relatively stable physicochemical properties of quartz sand, it was selected as the aggregate particle to satisfy the aforementioned requirements. The influence of montmorillonite on the disintegration of the clay mineral composition of the natural red-bedded soft rock to be modeled is critical, and montmorillonite was chosen as the clay mineral. The materials used to create similar specimens are as follows:
Sodium chloride
Montmorillonite particles (800 mesh)
STGP (with a melting point of 450 °C and a particle size of 800 mesh)
Quartz sand (a mixture of various particle sizes, including 40–70 mesh (35%), 70–110 mesh (10%), 110–200 mesh (20%), and 200–300 mesh (35%)).
The roles of each material are as follows: quartz sand acts as the aggregate; sodium chloride is used to create a saturated solution that acts as a cementing agent, which, under 105 °C conditions, crystallizes and causes a cementing effect with the surrounding particles. Sodium chloride dissolves when encountering water, whereas montmorillonite swells when absorbing water, resulting in uneven internal stress within the specimen. STGP melts at temperatures above its melting point and attaches to the surface of particles, promoting the movement and densification of the particles. After cooling and solidification, the surrounding particles are embedded and solidified.
As previously discussed, interparticle entrenchment is crucial for the gradual disintegration of similar materials, achieved by STGP forming entrenchments with the surrounding particles, which can only be accomplished by maintaining high-temperature and -pressure conditions for an extended period of time during the pressing and forming of the specimens. Therefore, to address this issue, a specimen preparation system that can create the necessary temperature and pressure conditions for the STGP to melt and form the required entrenchments was developed.
The system used for preparing the samples comprised a loading device, heating device, and sample-making mold, as illustrated in
Figure 3. The loading device incorporates an electric jack controlled by an intelligent system, whereas the heating device employs a high-temperature furnace also controlled by an intelligent system, thereby enabling continuous pressurization and heating for extended periods. The sample-making mold was designed and processed in-house and features a semi-open conical shape that facilitates sample retrieval and ensures consistent force application.
Zirconium oxide heat-insulation blocks with a low thermal conductivity of <2 were employed to isolate the mold barrel from the external environment and maintain a stable temperature inside the furnace. Copper pipes from an external water circulation circuit were wrapped around the jack piston rod to ensure its operation at a normal working temperature.
The parameters of the specimen preparation system are as follows:
Loading device: jack loading range of 0–125 MPa, with a piston rod diameter of 50 mm;
Heating device: high-temperature furnace with a heating range from room temperature to 800 °C and an accuracy of ±1 °C;
Sample-making mold: inner diameter of 50 mm, accuracy of ±0.01 mm, and height of 160 mm.
3.2. Orthogonal Design Test Protocol
Metamorphism of aggregate particles can occur owing to excessive temperatures and pressures, rendering the resulting samples no longer classified as sedimentary rocks [
22,
23,
24]. Previous literature [
25,
26] suggests that internal rock particles begin to metamorphose when temperatures exceed 600 °C, and mudstone and sandstone can reach near-metamorphic states at depths of burial greater than 1800 m (pressure > 35 MPa). Therefore, to prepare similar materials, it is important to ensure that the parameters satisfy certain conditions, such as pressure < 35 MPa and temperature < 600 °C.
Based on previous studies regarding the inversion of the sedimentary rock formation depth [
27], the natural rock samples for this simulation were buried at depths of 1000~1500 m. A sample preparation pressure of 30 MPa was chosen to simulate the overburden pressure during the formation of natural rock samples and ensure that the sample particles did not undergo metamorphic effects. The components of the similar material were determined based on the mineral composition of the natural rock sample to be simulated, as detailed in
Table 4.
Using the orthogonal design test method, four levels were selected for the three influencing factors: STGP content, heating temperature, and pressing time. The resulting material preparation test is presented in
Table 5.
3.3. Specimen Preparation Procedure and Test Content
To prepare similar materials, the corresponding masses of STGP, quartz sand, and montmorillonite powder were weighed according to the ratio and mixed thoroughly. Next, sodium chloride was added to the powder mixture until the color was homogeneous and the particles were moistened. The mixed powder was placed in a mold cylinder coated with high-temperature-resistant grease and pre-pressed at a load of 10 MPa for 15 min using a universal testing machine.
The pre-pressed mixed powder and the mold cylinder were then placed in a specimen preparation system and pressed at a mild pressure of 30 MPa. After pressing, the mold barrel was cooled to room temperature, and the specimens were slowly removed using a stripping machine. To ensure smoothness, the specimens were polished at both ends using a grinding machine and then dried in an oven at 105 °C until a constant weight was achieved for subsequent testing.
The uniaxial compression tests were first carried out on the prepared specimens according to the standard for engineering rock test methods (GB/T 50266-2013) [
28] to obtain the uniaxial compressive strength
and elastic modulus
of the specimens; after the uniaxial compression tests were completed, the remaining parts of the specimens were taken for disintegration resistance tests and SEM observations.
Figure 4 shows the details of these tests.
5. Conclusions
A technical approach for preparing similar materials that simulate the progressive disintegration of red-bedded soft rock was developed by simulating the rock-forming process and incorporating the STGP into the production process. A similar material was then pressed at a temperature and pressure that did not cause the aggregate to undergo metamorphic action and promoted the formation of similar material particles embedded during solidification. Subsequently, a corresponding sample preparation system was developed and experimentally verified, leading to the following conclusions:
- 9.
The dynamic and static disintegration processes of similar material specimens indicate that incorporating STGP is feasible for preparing a similar material with a disintegration process similar to that of natural rock samples. A similar material can simulate the disintegration process of a natural red-bedded soft rock well.
- 10.
Mixing STGP increased the density, compressive strength, and elastic modulus of similar material specimens while reducing the porosity ratio. The experiments demonstrated that similar materials made in the presented study have similar basic physical and mechanical properties compared with core red-bedded soft samples when the contents of STGP are 0.5–2%.
- 11.
The STGP content was identified as the key factor affecting the physical and mechanical properties and disintegration process of similar materials, based on the analysis of the physical and mechanical test results of similar materials in the experimental group.
- 12.
Scanning electron microscopic observations of specimens with different STGP content levels showed that the higher the STGP content, the smaller the particle spacing between the aggregates of similar material specimens, indicating that incorporating STGP can promote the formation of particles embedded in similar materials and result in the progressive disintegration of similar materials.
This study focused on the simulation of red-bedded soft rock formation and the preparation of a similar material that can progressively disintegrate by adding STGP to induce aggregate inlay formation. The results of this study provide valuable technical support for indoor model experiments on soft rocks with progressive disintegration characteristics.