Thin spray-on liners (TSL) is increasingly popular in underground mine support operations. In this study, a new type of TSL material is proposed, and its macro-micro physical and mechanical properties are characterized. A systematic investigation on the deformability behaviour of six rocks (i.e., coal rock, soft red sandstone, marble, hard sandstone, granite, and limestone) covered TSL materials with different curing ages (i.e., 0-day, 3-day, 7-day, 14-day, 21-day, and 28-day) under uniaxial compression circumstance is performed using acoustic emission (AE) and digital image correlation (DIC) methods. The results show that TSL improves the peak strain of each rock sample, except hard sandstone. The impact of TSL on the peak compressive strength of coal rock, soft red sandstone, and marble is nearly negligible, while it diminishes the strength of hard sandstone, granite, and limestone. As the TSL ages, the peak strength and elastic modulus of limestone initially increase and then decrease, reaching the minimum at 14-day of age, with values 89.81 MPa and 23.13 GPa respectively. However, for other rock samples, the effect of TSL age is not significant. The AE signal produced inside the rock diminishes during the elastic-plastic stage, while the ratio of shear cracks increases upon failure of each rock specimen. The macroscopic failure modes of coal rock and limestone exhibit prominent axial splitting characteristics, whereas marble and hard sandstone undergo mixed failure processes involving shear, tension, and shear-tension. The test data highly correspond to the macroscopic fracture characteristics. The research findings can serve as guidance for TSL support in both soft and hard rock scenarios.
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