Experimental study on fiber-reinforced cement tailings sand-based grouting material preparation and factors influencing the grouting effect

Abstract

To address the problem of permeation of tailings pond initial dams rockfill dams, fiber-reinforced cement tailings sand-based grouting (FRCTG) material, which can be used for rockfill dam reinforcement, was prepared by selecting ordinary portland cement (OPC), iron tailings sand (ITS), basalt fiber (BF), fly ash (FA) and water as the raw materials. Orthogonal tests were used to investigate the effects of the water-binder ratio (w/b) and material mass fraction on the rheological and mechanical properties of FRCTG and determine the optimum mixing ratio. Comparative analyses were performed of the grouting effect of FRCTG and pure OPC grouting materials based on concrete self-compacting tests and COMSOL simulations. Combined X-ray diffraction (XRD) and scanning electron microscopy-energy spectroscopy (SEM-EDS) microstructural characterization were used to reveal the factors influencing FRCTG mechanical properties. The results showed that when the water-binder ratio (w/b) was 0.5, ITS substitution percentage for OPC was 10 %, BF dosage was 0.2 %, BF length was 6 mm, and FA substitution percentage for OPC was 8 %, FRCTG had better rheological properties and flexural strength than pure OPC grouting materials. In addition, FRCTG self-compacting concrete also had stronger compressive strength and splitting strength. FRCTG showed a better filling capacity and diffusion effect, which preliminarily verified the feasibility of rockfill dam grouting. ITS inhibited the hydration reaction of the cementitious material and prolonged the setting time of the slurry. The interlocking structure formed by FA and hydration products indirectly enhanced the flexural strength of the grouting material. BF not only provided FRCTG reinforcement but also acted as the hydration product skeleton. FRCTG demonstrated better economic and environmental performance than traditional cement material while effectively utilizing ITS and FA solid waste.