Mix Proportion Optimization and Performance Evaluation of Bismuth Oxide/Clay Functional Shotcrete for Radiation Protection in Underground Spaces

To address underground shotcrete support scenarios with potential radiation-protection requirements, a bismuth oxide/clay functional filler was incorporated into a baseline shotcrete formulation. Functional filler dosage, calcium formate dosage, and PCE dosage were selected as variables, and Box–Behnken response surface methodology was used to establish quadratic regression models for 28 d compressive strength, fluidity, and bond strength. Representative optimized mixtures were further evaluated by MCNP5 simulation, gamma-ray air-kerma attenuation tests, and SEM. The models showed good fitting and predictive performance within the investigated design space. Functional filler dosage mainly controlled compressive strength and bond strength, whereas PCE dosage dominated fluidity. Under the constraints of compressive strength ≥ 25 MPa, fluidity of 160–170 mm, and bond strength ≥ 0.8 MPa, three representative mixtures were selected for shielding-, strength-, and interface-priority strategies. Simulated and measured results showed consistent shielding-performance rankings, and the optimized mixtures exhibited higher gamma-ray attenuation than the blank mixture. BBD26 achieved the highest shielding performance, with measured shielding rates of 65.51% and 51.54% at 661.7 keV and 1.25 MeV, respectively. Thickness-gradient tests indicated exponential attenuation, while SEM revealed differences in Bi-bearing particle distribution and matrix continuity.