Influence and Mechanism of Coal Gangue Sand on the Properties and Microstructure of Shotcrete Mortar

Coal gangue, a fine aggregate for the preparation of shotcrete mortar, is a cost-effective approach for the resource utilization of coal gangue. This study employed a mortar setting time tester, electronic universal testing machine, water absorption tester, nitrogen adsorption-desorption instrument (BET), X-ray diffraction (XRD), scanning electron microscopy (SEM), and life cycle assessment (LCA) to investigate the effects and mechanisms of replacing natural sand with coal gangue sand (0-100%) under water-to-binder ratios of 0.4 and 0.55 on the macroscopic properties, microstructure, and environmental impact of shotcrete mortar. The results showed that the porous nature of coal gangue sand increased the porosity of shotcrete mortar and reduced its compressive strength. However, its water absorption effectively decreased the effective water-to-binder ratio, significantly shortening the initial setting time. At a water-to-binder ratio of 0.55, as the replacement ratio of coal gangue sand increased from 0% to 100%, the porosity of shotcrete mortar increased by approximately 30%, the compressive strength decreased by about 40%, and the initial setting time was shortened by 57%. When the water-to-binder ratio was reduced to 0.4 and the replacement ratio of coal gangue sand was 50%, the shotcrete mortar met the application requirements of M20 shotcrete mortar, with an initial setting time of less than 12 min and a compressive strength of over 23 MPa after 28 days of water curing. Microstructural analysis revealed that the absorbed water in coal gangue sand played an internal curing role during cement hardening, improving the compactness of the interfacial transition zone. Environmental assessment results indicated that, under the same strength conditions, the life cycle environmental impact of coal gangue sand shotcrete mortar was approximately 70% lower than that of natural sand shotcrete mortar. This study provides a theoretical basis for the efficient resource utilization of coal gangue and the preparation of low-carbon shotcrete mortar.