Utilizing Crushed Limestone as a Sustainable Alternative in Shotcrete Applications

Solving the challenges facing the mining industry is crucial for shaping the global attitude towards clean energy technologies associated with critical minerals extracted from depth. One of these challenges is the well-known explosion-like fractures (rockbursts) or spalling failures associated with the initiation of internal cracks. To prevent such catastrophic failure, shotcrete, as a cement grout, is widely used in tunnel support applications. In areas where the tunnels are constructed within the limestone strata using tunnel boring machines (TBM), drilling, and/or blasting, millions of cubic meters of crushed limestone (CL) in powder form are extracted and landfilled as waste. Given the fact that natural sand consumption as a raw material in the construction industry exceeds previous records, recycling of such excavation material is now becoming increasingly needed. From this perspective, this study aims to utilize crushed limestone as a potentially sustainable alternative to natural sand in shotcrete applications in deep tunnels. Accordingly, several strength characterization and crack initiation determinations through various stress-strain-based models were carried out on cylindrical samples containing different proportions of crushed limestone. By increasing the crushed limestone content in the shotcrete mix, the crack initiation stress (as a measure of the in situ spalling strength) increased as well. The results suggest that the crushed limestone has good potential to replace the natural sand in the shotcrete mixture used in tunnel support applications.