This study addresses the challenges of excessive fluidity and poor bonding performance in ultraretarded solidification mine tailings waste-based shotcrete. The research investigates the fundamental mechanical properties of this material by optimizing the proportions of mineral powder (A), soil-rock waste (B), and water content (C). Comprehensive analysis was conducted through mechanical property testing, scanning electron microscopy (SEM), and X-ray diffraction (XRD) to elucidate the hydration mechanisms. The results demonstrate that a mineral powder content of 20 % (A1B2C3 to A1B1C1) yields optimal performance, with compressive, splitting tensile, and flexural strengths reaching 138.5 %, 163 %, and 154 % of baseline values, respectively. Maximum compressive strengths of 16.12 MPa, 24.18 MPa, and 32.08 MPa were achieved under specific mix conditions (C1A1B1). Additionally, increasing the content of A and C was found to extend the setting time of the cementitious material. The optimal mix ratio, comprising 20 % A, 25 % B, and 4 % C, exhibited enhanced hydration degree and superior macroscopic performance. Field construction tests confirmed that the material's viscosity, fluidity, and rapid-setting properties meet practical engineering requirements.

Shotcrete plays a pivotal role in the construction of tunnels and underground structures; however, its inherent brittleness necessitates reinforcement to enhance ductility. This research explores the use of fiber-reinforced shotcrete as primary tunnel support to enhance ductility and reduce brittleness. Traditional steel mesh reinforcement complexities have led to the investigation of alternative materials. The research evaluates different fiber mix designs, including industrial steel, recycled steel fibers from tires, and Forta fibers, examining their strength parameters and deformation performance. A 3D finite element model is used to simulate a horseshoeshaped tunnel with optimal mix design and plain shotcrete in a soil environment. The study finds that hybrid industrial and recycled fibers are more effective than single fibers, enhancing compressive, tensile, and flexural strength and reducing ground surface settlement and tensile damage. The optimal mix design of this study has increased compressive, tensile, and flexural strength, as well as flexural toughness, compared to plain shotcrete. Numerical modeling reveals that utilizing fiber reinforced shotcrete made out of optimal fiber mix design as primary support results in a significant reduction in ground surface settlement and tensile damage value. Furthermore, the study shows a significant reduction in the damaged zone area under tensile stresses. The results of the study highlight the potential of fiber reinforced shotcrete as a primary support for tunnels, leading to improved performance and sustainability in tunnel construction.

This paper describes the relevant research activities that are being carried out on the development of a novel shotcrete technology capable of applying, autonomously and in real time, fibre reinforced shotcrete (FRS) with tailored properties regarding the optimum structural strengthening of railway tunnels (RT). This technique allows to apply fibre reinforced concrete (FRC) of strain softening (SSFRC) and strain hardening (SHFRC) according to a multi -level advanced numerical simulation that considers the relevant nonlinear features of these FRC, as well as their interaction with the surrounding soil, for an intended strengthening performance of the RT. Building information modelling (BIM) is used for assisting on the development of data files of the involved design software, integrating geometric assessment of a RT, damages from inspection and diagnosis, and the characteristics of the FRS strengthening solution. A dedicated computational tool was developed to design FRC with target properties. The preliminary experimental results on the evaluation of the relevant mechanical properties of the FRS are presented and discussed, as well as the experimental tests on the bond between FRS and current substrates found in RT. Representative numerical simulations were performed to demonstrate the structural performance of the proposed FRS -based strengthening technique. Computational tools capable of assuring, in real time, the aimed thickness of the layers forming the FRS strengthening shell were also developed. The first generation of a mechanical device for controlling the amount of fibres to be added, in real time, to the FRS mixture was conceived, built and tested. A mechanism is also being developed to improve the fibre distribution during its introduction through the mechanical device to avoid fibre balling. This work describes the relevant achievements already attained, as introduces the planned future initiatives in the scope of this project.