Uniaxial Damage Mechanisms in Roller-Compacted Concrete Subjected to Freeze–Thaw Cycles

Water-retaining roller-compacted concrete (RCC) dams suffer severe deterioration under coupled moisture ingress and freeze–thaw (F-T) cycles. To elucidate the damage mechanisms, this study employed industrial X-ray computed tomography (CT) synchronized with uniaxial compression and acoustic emission (AE) monitoring. The cross-scale damage evolution of RCC was investigated under dry, water-saturated, 25, and 50 F-T cycle conditions. The results indicate the following: (1) Macroscopically, F-T damage causes linear peak stress attenuation, shifting the failure mode from brittle axial splitting to ductile oblique shear. (2) Mesoscopically, frost-heaving stress expands native mesopores (500–2500 μm), increasing their volume fraction from 8.45% to 14.86% and remodeling isolated voids into a 3D interconnected defect network. (3) Microscopically, GMM-based AE clustering reveals a fracture transition. Driven by moisture lubrication and defect propagation, global shear cracks surpass the 50% threshold at 25 cycles (53.5%), reaching 68.6% at 50 cycles. (4) For cross-scale mapping, calibrating the AE b-value via Aki’s method decouples pore-water signal attenuation. Its pre-peak characteristic (an initial decrease followed by a rebound) accurately maps microcracks unstably coalescing along interconnected pores to form macroscopic shear planes. This cross-scale mechanism provides a scientific paradigm for condition monitoring of massive concrete in cold regions.