Multi-Scale Investigation of Fracture Behavior of Polypropylene Fiber-Reinforced Concrete Segment During Bending Test

Polypropylene fibers provide an innovative solution for enhancing the crack resistance of tunnel lining segments. However, existing macro-models obscure the distinct effects of fibers on the mortar and ITZ, while explicit meso-modeling remains computationally prohibitive. This study develops a multi-scale modeling framework to investigate PFRC segment fracture under bending. The framework integrates a 3D meso-scale module for calibrating fracture-related material properties, a 3D macro-scale module for predicting global displacements, and a 2D meso-scale module for resolving local fracture processes. A full-scale bending test was performed to validate the framework and to examine the effects of fiber content at both scales. Both the full-scale test and numerical simulations show that the segment response exhibits three stages: elastic, damage development, and cracking at the design load. Numerical simulations further reveal that an optimal fiber content of 0.4% reduces the vertical displacement at the load point by 9.8% and the horizontal displacement at the edge point by 2.9% relative to the fiber-free case. Meso-scale simulations show that 0.4% fibers decrease the bottom crack width from 0.0868 to 0.0770 mm (−11.29%) and limit internal crack connectivity. Although fibers may locally promote ITZ cracking due to reduced mortar–aggregate bonding, a strengthened mortar matrix suppresses crack penetration and connected crack networks. A pronounced high-damage peak in the ITZ near the failure threshold confirms the ITZ as the governing weak link; therefore, further improvements may require ITZ-strengthening strategies.