Interfacial Shear Fatigue and Damage Evolution of Epoxy-Emulsified Asphalt Bond Coats Under Coupled Effects of Temperature, Loading Frequency and Stress Level

Interfacial bond failure is a common form of distress in rigid–flexible composite pavements, especially in tunnel environments with harsh service conditions. Epoxy-emulsified asphalt (EEA) is widely used as a high-performance interlayer bond coat, but its dynamic damage evolution under coupled thermomechanical loading remains insufficiently characterised. In this work, 45° static oblique shear tests and stress-controlled dynamic shear fatigue tests were performed on a C40 concrete-EEA-asphalt mixture composite system. Tests covered a temperature range of −10 °C to 45 °C, loading frequencies of 1 to 15 Hz, and three stress levels (0.3, 0.4, 0.5). An optimised geometric tangent method (GTM) was adopted to objectively locate the fatigue failure inflexion point, reducing the empirical bias inherent in traditional stiffness degradation analysis. Test results showed that an EEA application rate of 0.8 kg/m2 yielded the best overall interface performance, balancing mechanical interlocking and cohesive strength. At this application rate, the interfacial peak shear strength reached 1.72 MPa, with improved interfacial deformation compatibility and energy dissipation capacity. Fatigue damage followed a distinct three-stage stiffness degradation pattern. High temperatures and low loading frequencies accelerated rheological behaviour of the asphalt phase, shortened the stable damage propagation phase, and promoted premature interlayer slippage. Based on the experimental data, a phenomenological fatigue life prediction model was established, incorporating temperature, loading frequency and stress level. The model supports quantitative assessment of progressive interfacial damage and provides practical reference for structural durability design and life-cycle maintenance of composite tunnel pavements.