Cemented Sand, Gravel, and Rock (CSGR) dams have traditionally used either Conventional Vibrated Concrete (CVC) or Grout-Enriched Roller Compacted Concrete (GERCC) for protective and seepage control layers in low- to medium-height dams. However, these methods are complex, prone to interference, and uneconomical due to significant differences in the expansion coefficient, elastic modulus, and hydration heat parameters among CSGR, CVC, and GERCC. This complexity complicates quality control during construction, leading to the development of Grout-Enriched Vibrated Cemented Sand, Gravel, and Rock (GECSGR) as an alternative. Despite its potential, GECSGR has limited use due to concerns about freeze-thaw resistance. This project addresses these concerns by developing an air-entrained GECSGR grout formulation and construction technique. The study follows a five-phase approach: mix proportioning of C1806 CSGR; optimization of the grout formulation; determination of grout addition rate; evaluation of small-scale lab samples of GECSGR; and field application. The results indicate that combining 8-12% of 223 kg/m3 cement grout with 2-2.23 kg/m3 of admixtures, mud content of 15%, a marsh time of 26-31 s. and a water/cement ratio of 0.5-0.6 with the C1806 parent CSGR mixture achieved a post-vibration in situ air content of 4-6%, excellent freeze-thaw resistance (F300: mass loss <5% or initial dynamic modulus ≥60%), and permeability resistance (W12: permeability coefficient of 0.13 × 10-10 m/s). The development of a 2-in-1 slurry addition and vibration equipment eliminated performance risks and enhanced efficiency in field applications, such as the conversion of the C1804 CSGR mixture into air-entrained GECSGR grade C9015W6F50 for the 2.76 km Qianwei protection dam. Economic analysis revealed that the unit cost of GECSGR production is 18.3% and 6.33% less than CVC and GERCC, respectively, marking a significant advancement in sustainable cement-based composite materials in the dam industry.
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