Innovative Compositions of Shotcrete Mixtures for Reinforcement of Underground Mine Excavations

The objective of this article is to develop a polymer-modified shotcrete composition to improve underground mine support. The authors propose a new formulation by integrating an aqueous emulsion of SKS-65 GP grade B latex into cementitious matrices. Methods include X-ray diffraction, particle-size analysis, rheological testing, mechanical strength tests, numerical modeling, in-situ trials at the Zholbarysty mine, and statistical evaluation. Findings show a 45% increase in compressive strength and a 30% reduction in rebound loss compared to standard mixtures. Field core samples confirmed reproducibility, with strength values within 1% of those from laboratory-tested cubes. The improved mix allows a 50% reduction in lining thickness, expanding the tunnel cross-section by 5% and lowering operational costs by 39%. Cost-benefit analysis and cross-sectional evaluation validate the approach's efficiency. The novelty of this work lies in combining microstructural insights with field-scale application, clarifying polymer-film formation mechanisms, and presenting an optimized, scalable shotcrete mix design. This integrated method provides a practical and cost-effective reinforcement solution, advancing current shotcrete technologies for underground operations.