Experimental investigation and fluid-structure interaction modelling of the casting of self-compacting concrete for CRTS III slab track in the curved segments

Ensuring the casting quality of self-compacting concrete (SCC) is crucial for the operational safety and durability of China railway track system (CRTS) III slab track. However, the mechanisms of key factors influencing flow behaviors of SCC and structural responses remain insufficiently understood, nor is the relationship between flow behaviors and structural responses during casting. In this study, fluid-structure interaction (FSI) models of SCC casting were developed and verified by full-scale physical tests, comprising slump flow, L-box flow and casting of SCC in an actual track at the field of Laixi-Rongcheng high-speed railway. Through in-depth analysis on the casting process of SCC in curved segments with a super elevation of 80 mm, the relationship between flow behaviors and structural responses was established. Furthermore, the influence mechanisms of key factors on flow behaviors and structural responses were investigated systematically. Results show that during gravity-fed SCC casting, its flow velocity diminishes, thus increasing the static pressure and the forces exerted on the slab by SCC. These vertical and lateral forces increase to 147.16 and 7.83 kN through three stages of development, acceleration and stabilization, resulting in commensurate structural responses. At the end of casting process, the central region of the slab exhibits maximum vertical deformation of 0.95 mm and tensile stress of 1.07 MPa. The tension rods at the side with lower elevation bear greater vertical and lateral forces than the ones at the side with higher elevation. The rise of funnel height from 1.05 to 1.35 m accelerates the casting process but increases the forces exerted by SCC by up to 26 % and augments the associated response of entire structures, whereas the funnel diameter shows little effect. Increasing yield stress of SCC from 9.3 to 49.3 Pa produces a more uniform flow morphology and thus higher static pressure and force by SCC in the middle region of the slab, impacting the structural responses by up to 15 %. The growth of plastic viscosity from 59 to 99 Pa⋅s significantly affects the volume rate and casting time by up to 66 % but has little effect on the flow morphology, fluid pressure and structural responses. In order to ensure high quality casting of SCC, five clamping beams are suggested with two beams positioned at either side of the slab and the other three evenly placed along the middle region of the slab. • FSI models of SCC casting in curved segments were developed for the first time. • Correlation of flow indicators with structural responses was analyzed during casting. • Fluid pressure associate with funnel and SCC plays key role in casting quality. • Higher yield stress of SCC causes more homogenous flow and lager fluid pressure. • Mechanism of clamping beams affecting structural responses was revealed innovatively.