Search Results (48)

This study examines freeze–thaw deterioration patterns and predicts the service life of wet-sprayed concrete with composite cementitious materials in cold-region tunnels. The microstructure and particle size distribution of four materials (cement, fly ash, silica fume, and mineral powder) were analyzed. Subsequent tests evaluated the rebound rate, mechanical properties, and durability of wet-sprayed concrete with various compositions and proportions of cementitious materials, emphasizing freeze–thaw resistance under cyclic freezing and thawing. A freeze–thaw deterioration equation was developed using damage mechanics theory to predict the service life of early-stage wet-sprayed concrete in tunnels. The results indicate that proportionally combining cementitious materials with different particle sizes and gradations can enhance concrete compactness. Adding mineral admixtures increases concrete viscosity, effectively reducing rebound rates and dust generation during wet spraying. Concrete incorporating binary and ternary mineral admixtures shows reduced early-age strength but significantly enhanced later-age strength. Its frost resistance is also improved to varying degrees. The ternary composite binder fills voids between cement particles and at the interface between paste and aggregate, resulting in a dense microstructure due to a ‘composite superposition effect.’ This significantly enhances the frost resistance of wet-mixed shotcrete, enabling it to withstand up to 200 freeze–thaw cycles, compared to failure after 75 cycles in plain cement concrete. The relative dynamic modulus of elasticity of wet-shotcrete follows a parabolic deterioration trend with increasing freeze–thaw cycles. Except for specimen P5 (R² = 0.89), the correlation coefficients of deterioration models exceed 0.94, supporting their use in durability prediction. Simulation results indicate that, across all regions of China, the service life of wet-shotcrete with ternary admixtures can exceed 100 years, while that of plain cement concrete remains below 41 years. Full article

Shotcrete, due to its excellent performance, has become widely adopted as a lining material in tunnel construction. However, research on the fracture behavior of shotcrete, especially in terms of precise fracture toughness determination methods, remains limited. In this study, three distinct batches of shotcrete with varying porosities were fabricated, and their fracture properties were evaluated using three-point bending tests. A closed-form solution was developed to calculate the fracture toughness of shotcrete used in tunnel linings, incorporating factors such as micro-structure, specimen boundaries, and geometry. The results demonstrated that the fracture toughness obtained through this method can be treated as a material constant, independent of specimen geometry. Additionally, the study emphasized the importance of considering the pore structure in the design and fracture analysis of shotcrete materials. Full article

Straw as a building material alternative is in line with sustainable development goals. To make effective use of straw resources such as rice and corn stalks in rural areas, a kind of steel wire mesh-reinforced straw concrete sandwich panel (SCSP) was developed. The SCSP was composed of cold-drawn low-carbon steel-wire mesh (SWM), fine gravel concrete (FGC), and straw. The used type of FGC was shotcrete. A cold-drawn low-carbon SWM was arranged on the upper and lower sides of the SCSP, and a vertical wire tie was arranged between the upper and lower cold-drawn low-carbon SWMs. The FGC was sprayed on the SWM to make the SCSP layer work together. The loading process of the SCSP could be divided into three stages: elastic working state, cracking state, and failure state. The results of the four-point loading test show that the maximum flexural moment of the SCSP can be up to 7.5 kN·m in the elastic range. The ultimate bearing capacity of SCSP reaches 10.9 kN·m, and the maximum crack width can reach 3~4 mm. At the same time, based on the assumption of the flexural section of SCSP, two simplified calculation models of SCSP bearing capacity were established. The average error was 2.99% and 9.41%, respectively, by comparing the experimental values with the two calculated values. The results obtained by using the two models were in good agreement with the experimental results. Full article

Tunnel Boring Machine (TBM) excavation materials were recycled by sieving and separating particles into sizes 5–10 mm (coarse aggregates) and below 5 mm (manufactured sand) to explore their potential as aggregates in shotcrete production, with the aim of reducing environmental harm from waste disposal. Mix proportion experiments were conducted to evaluate the mechanical properties—including failure patterns, compressive strength, flexural strength, and deflection—of the shotcrete specimens through cubic axial compression and four-point bending tests; furthermore, rebound tests were conducted on shotcrete mixed with the recycled TBM aggregates in foundation pit engineering. These tests assessed the effects of key parameters (water–binder ratio, sand ratio, fly ash content, synthetic fibers, and liquid alkali-free accelerator) on shotcrete composed of recycled TBM sand and gravel. The results indicated that crushing and grading flaky TBM-excavated rock fragments, and subsequently blending them with pre-screened fine aggregates in a 4:1 ratio, yielded manufactured sand with an optimized particle gradation and controlled stone powder content (18%). Adjusting the water–binder ratio (0.4–0.5), fly ash dosage (mixed with 0–20%), and sand ratio (0.5–0.6) are feasible steps in preparing shotcrete with a compressive strength of 29.1 MPa to 50.4 MPa and slump of 9 cm to 20 cm. Moreover, the rebound rate of the shotcrete reached 11.3% by applying polyoxymethylene (POM) fibers with a 0.15% volume fraction and a liquid-state alkali-free setting accelerator (8% dosage), demonstrating that the implemented approach enables a decrease in the rebound rate of shotcrete. Full article

Shotcrete is a versatile construction material, yet its performance limitations, such as high rebound rates and poor adhesion, demand technological improvements to ensure structural reliability. Silicon manganese (SiMn) slag, a by-product of SiMn alloy production, has gained attention as a potential sustainable alternative to natural aggregates in construction materials, addressing both resource depletion and carbon reduction challenges in the industry. This study is conducted to develop and evaluate a new mix design of mortar incorporating SiMn slag as fine aggregate, focusing on enhancing performance. Mixtures with varying percentages (0%, 30%, 50%, 70%, and 100%) of SiMn slag as a fine aggregate replacement were evaluated for fresh properties (air content, slump), mechanical performance (compressive strength, flexural strength, splitting tensile strength), durability (chloride ion penetration resistance, freeze–thaw resistance, carbonation resistance), and constructability (rebound rate, free shrinkage) to assess suitability as mortar for shotcrete. The experimental results demonstrated that the mixture with 50% SiMn slag replacement demonstrated the most balanced performance, showing an increase of 12.33% in compressive strength, 8.97% in splitting tensile strength, and 18.4% in flexural strength compared to the control. Durability properties also improved by an average of 11.93%, while rebound rate and shrinkage were significantly reduced. The findings confirm that SiMn slag is a technically viable and advantageous substitute for fine aggregates in shotcrete. Further research is needed to refine its economic feasibility and broaden its implementation in sustainable construction. Full article

Conventional shotcrete systems face critical limitations in adverse geological environments, including a delayed strength development (<5 MPa at 3 h), excessive rebounds (15–25%), and permeable macropore networks (>50 μm), often resulting in support failure for deeply buried tunnels. To address these challenges, this study systematically investigates the mechanical properties and pore characteristics of a manufactured sand-based sprayed UHPC at different spraying positions under simulated tunnel conditions. Our results demonstrate that the high-pressure air (0.8 MPa) driven spraying process optimizes its pore distribution, reducing large pores (>10 μm) and increasing harmless pores (<100 nm). Furthermore, the sprayed UHPC incorporating manufactured sand derived from tunnel slag not only maintains a 28-day compressive strength of 110.9 MPa but also reduces material costs and enhances sustainability. Field tests validate its low rebound rate (<5%) and rapid strength development (achieving a compressive strength of 30 MPa within 1 day), confirming its adaptability to complex geological conditions such as high-stress zones, thereby providing a novel method for support in complex geological conditions. Full article

To maximize the comprehensive utilization of gangue waste, broken gangue can be used to replace gravel as the coarse aggregate to prepare underground roadway shotcrete, and treated gangue powder can be used for the partial replacement of cement. This not only diminishes the demand for conventional raw materials but also increases the amount of gangue waste disposed. Broken gangue waste was ball-milled for 1 h, 3 h, and 5 h to prepare gangue powder, which was used to partially replace cement. Then, experimental schemes for the performance of shotcrete at the rates of cement replacement of 30%, 40%, and 50% were devised to compare the mineral compositions and microscopic characteristics of shotcrete with the partial replacement of cement with gangue powder. The influences of the partial replacement of cement with gangue powder on the slump, tensile strength, and compressive strength of the shotcrete were revealed. The experimental results revealed an inverse relationship between shotcrete slump and both the cement replacement ratio and the gangue Ball-milling duration. Increasing the cement replacement ratio from 30% to 50% reduced slump by 55.3% (103 mm → 46 mm), while extending the Ball-milling time from 1 h to 5 h decreased it by 33.0% (103 mm → 69 mm). Mechanical properties showed contrasting trends: After a 28-day curing process, compressive and tensile strengths declined by 54.5% (20.18 → 9.18 MPa) and 40.4% (1.56 → 0.93 MPa), respectively, with a higher cement replacement ratio. Conversely, prolonged Ball-milling duration improved the compressive strength by 12.8% (18.68 → 21.07 MPa) and the tensile strength by 34.1% (1.26 → 1.69 MPa). Moreover, the shotcrete meets the strength requirements for engineering applications only when the cement replacement ratio is 30% with gangue ball-milling durations of 3 h and 5 h. The research provides strong support for the performance optimization of gangue-based shotcrete and the improvement of the utilization of gangue waste. Full article

Defects can be introduced into shotcrete materials after a few freeze–thaw cycles, which has a significant influence on the fracture performance of shotcrete. In this study, a series of shotcrete specimens with varying sizes, geometries, and initial crack lengths were prepared to investigate the fracture properties of notched shotcrete under freeze–thaw conditions. Considering the effects of specimen boundaries and material microstructure, a linear closed-form solution was proposed to determine the fracture toughness of frost-damaged shotcrete. The fracture toughness was found to be a reliable material constant, independent of specimen geometry variations. Results from three-point bending (3PB) tests show that freeze–thaw cycles severely weaken the fracture toughness of shotcrete, which is consistent with CT scan images of the damaged microstructure of the shotcrete specimens. Moreover, specimens with longer initial notches exhibited more severe freeze–thaw damage, which should be carefully considered in practical engineering assessments. These findings highlight the critical importance of considering freeze–thaw effects and notch length when evaluating the durability of shotcrete in cold region applications. Full article

This study substantiates the need for direct tensile strength testing of shotcrete and fiber-reinforced shotcrete, rather than relying on indirect methods, to accurately reflect material performance under biaxial stress conditions when used for structural reinforcement. Experiments on field specimens confirmed that tensile strength values derived through direct testing differ significantly from those calculated based on compressive strength. The study presents a new testing methodology with optimized specimen dimensions (32, 40, 50, and 82 mm diameter cylinders with length-to-diameter ratios of 3.0) to mitigate eccentricity effects, ensuring normal-section failure. Results show that tensile strength values for fiber-reinforced shotcrete with brass-coated fibers (13–15 mm length, 0.3–0.5 mm diameter, 30 kg/m³ dosage) reached 68 MPa, compared to 60 MPa for standard shotcrete, while basalt-fiber reinforcement (6 mm length, 1% by weight) resulted in 42 MPa. The initial modulus of elasticity for unreinforced shotcrete was 280 × 10³ MPa, with fiber reinforcement slightly increasing this value to 287 × 10³ MPa. The findings support a direct approach to testing, providing a foundation for developing predictive methodologies for fiber-reinforced shotcrete properties based on reinforcement type and dosage. These results are essential for applications such as seismic strengthening, where accurate tensile characteristics are critical for performance under dynamic loading. Full article

One of the primary and still unresolved problems of shotcreting is the high rebound rate of the material, which reaches over 20% in “dry” shotcreting. There is a practical need to improve the very principle of shotcreting and methods for optimizing the movement of torch particles. Materials and Methods: The purpose of this study was to justify the use of the electrostatic treatment of cement–sand mortar in the process of performing shotcreting works using the dry method. It was proposed that the binder and then the finished mixture be ionized step-by-step (by passing it through a non-uniform electrostatic field formed by corona electrodes). As a result, the shotcrete will be held on the fence. Results: Analysis of the modeling results shows that the presence of an electrostatic field slows down the particle and reduces the kinetic energy of the rebound. After theoretical calculations, experiments were conducted, during which, the torch size and the plant productivity were changed, and the rebound mass was weighed. After application to the surface, prototypes were formed and subjected to strength tests. It was determined that gunning in a sharply non-uniform electric field demonstrates its practical and economic efficiency due to the uniform deposition of charged particles on the treated surface and low power consumption. Conclusions: It was established that the electrostatic treatment of a cement–sand mixture during application allows concrete particles to be retained on the shotcrete surface, the rebound of the material to be reduced and the strength of concrete to be increased. Full article

This study investigates the impact of polyvinyl alcohol (PVA) fibers on the mechanical properties and durability of high-performance shotcrete (HPS). Results demonstrate that PVA fibers have a dual impact on the performance of HPS. Positively, PVA fibers enhance the tensile strength and toughness of shotcrete due to their intrinsic high tensile strength and fiber-bridging effect, which significantly improves the material’s splitting tensile strength, deformation resistance, and toughness, and the splitting tensile strength and peak strain have been found to be increased by up to 30.77% and 31.51%, respectively. On the other hand, the random distribution and potential agglomeration of PVA fibers within the HPS matrix can lead to increased air-void formations. This phenomenon raises the volume content of large bubbles and increases the average bubble area and diameter, thereby elevating the pore volume fraction within the 500–1200 μm and >1200 μm ranges. Therefore, these microstructural changes reduce the compactness of the HPS matrix, resulting in a decrease in compressive strength and elastic modulus. The compressive strength exhibited a reduction ranging from 10.44% to 15.11%, while the elastic modulus showed a decrease of between 8.09% and 12.67%. Overall, the PVA-HPS mixtures with different mix proportions demonstrated excellent frost resistance, chloride ion penetration resistance, and carbonation resistance. The electrical charge passed ranged from 133 to 370 C, and the carbonation depth varied between 2.04 and 6.12 mm. Although the incorporation of PVA fibers reduced the permeability and carbonation resistance of shotcrete, it significantly mitigated the loss of tensile strength during freeze–thaw cycles. The findings offer insights into optimizing the use of PVA fibers in HPS applications, balancing enhancements in tensile properties with potential impacts on compressive performance. Full article

The feasibility of using crushed limestone instead of sand in cement grout is examined in this work. This study entails performing several tests, including the Brazilian test, the compressive strength test, and the stress–strain correlation test. The curing times used were 7, 14, and 28 days for mixtures with various proportions of cement to limestone (1:1, 1:2, and 1:4). The conventional sand–cement grout laboratory tests were prepared using a similar methodology to examine the effectiveness of the suggested substitute. The findings show that the limestone-based grout has sufficient strength, but that it is less than that of the typical sand material. The values of the tensile strength and elastic modulus were determined. A focus was made on the tensile strength and stress–strain relationship. A special laboratory set-up was used to look at the progress of failure using strain gauges fitted to the cylindrical samples both vertically and horizontally. The angular shape of the particles’ ability to interlock is responsible for the material’s increase in strength. According to this study, crushed limestone can be used as a substitute for sand in circumstances where sand supply is constrained. The suggested grout can be used in the shotcrete of tunnels and rock surfaces. Full article

To improve the performance of shotcrete in high-altitude and low-temperature environments, emulsified asphalt shotcrete (EASC), which can be used in negative-temperature environments, was prepared by using low-freezing-point emulsified asphalt, calcium aluminate cement, and sodium pyrophosphate as modified materials. The effect of emulsified asphalt on the performance of shotcrete was investigated through concrete spraying and indoor tests. Then, the modification mechanism of emulsified asphalt with respect to EASC was analyzed by combining scanning electron microscopy images and the pore structure characteristics of EASC. The results showed that in a negative-temperature environment, the incorporation of emulsified asphalt delayed the formation of the peak of the cement hydration exotherm, slowed the rate of the cement hydration exotherm, reduced the thermal perturbation of permafrost by EASC, increased the cohesion of the concrete, improved the bond strength between EASC and permafrost, and reduced the rate of rebound. The mechanical strength of the studied EASC decreased upon increasing the amount of emulsified asphalt in the admixture, and its resistance to cracking gradually improved. A content of less than 5% emulsified asphalt could improve the internal pore structure of EASC, thus improving its durability. Increasing the content of emulsified asphalt affected the hydration process of the cement, and the volume content of the capillary pores and macropores increased, which reduced the durability of the EASC. Full article

This study aims to explore the static mechanical characteristics of coral aggregate seawater shotcrete (CASS) using an appropriate mix proportion. The orthogonal experiments consisting of four-factor and three-level were conducted to explore an optimal mix proportion of CASS. On a macro-scale, quasi-static compression and splitting tests of CASS with optimal mix proportion at various curing ages employed a combination of acoustic emission (AE) and digital image correlation (DIC) techniques were carried out using an electro-hydraulic servo-controlled test machine. A comparative analysis of static mechanical properties at different curing ages was conducted between the CASS and ordinary aggregate seawater shotcrete (OASS). On a micro-scale, the numerical specimens based on particle flow code (PFC) were subjected to multi-level microcracks division for quantitive analysis of the failure mechanism of specimens. The results show that the optimal mix proportion of CASS consists of 700 kg/m³ of cementitious materials content, a water–binder ratio of 0.45, a sand ratio of 60%, and a dosage of 8% for the accelerator amount. The tensile failure is the primary failure mechanism under uniaxial compression and Brazilian splitting, and the specimens will be closer to the brittle material with increased curing age. The Brazilian splitting failure caused by the arc-shaped main crack initiates from the loading points and propagates along the loading line to the center. Compared with OASS, the CASS has an approximately equal early and low later strength mainly because of the minerals’ filling or unfilling effect on coral pores. The rate of increase in CASS is swifter during the initial strength phase and decelerates during the subsequent stages of strength development. The failure in CASS is experienced primarily within the cement mortar and bonding surface between the cement mortar and aggregate. Full article

Coal gangue is a waste product commonly produced during coal mining. Using gangue as a replacement for conventional aggregates in shotcrete applied to underground roadways is a feasible approach to promote the resource utilization of gangue solid waste. The mix proportions of shotcrete materials are crucial to the effectiveness of field applications. The aim of this study was to investigate the effects of mix proportions on the mechanical properties of the gangue-based shotcrete material applied to roadways. To achieve this, we conducted experiments to measure changes in the slump under different gangue sizes, mass concentrations, sand contents, and cement contents. The study analyzed the influences of various mix proportions on the conveying and mechanical properties of the gangue-based shotcrete material applied to roadways. The slump and the compressive strength were analysed. The following was concluded: (1) The gangue size and sand content have a similar effect on the slump. As the gangue size and sand content increase, the slurry slump initially decreases and then increases, which is attributed to the plasticity of the aggregates themselves. The mass concentration has a negative correlation with the slump, which is the least sensitive to changes in cement content. (2) The compressive strength of all specimens increases with prolonged curing, reaching its maximum after 28 d under the compressive experimental conditions. (3) This paper analyzed the reasons for better mechanical properties under the conditions of smaller size gangue, higher mass concentration, and higher cement content. It has also examined the reasons for greater compressive strength at 35% sand content. The experimental results of this paper also offer relevant guidance regarding the specific mix proportions of the material of the field gangue-based shotcrete material applied to roadways. Full article