Rapid Repair Epoxy Mortar Fully Replacing Natural Aggregate and Filler with Graded Iron Tailings: Performance and Reinforcement

Numerous studies have investigated the application of iron tailings as raw materials for cement concrete, while rare efforts have been devoted to developing epoxy pavement repair mortars where graded IT function simultaneously as fine aggregate and filler. This study prepared epoxy resin mortar for rapid repair of cement concrete pavement using graded iron tailings (IT) as fine aggregate and filler. All mixtures employed IT as fine aggregate, where the mass proportion of IT filler relative to the total IT mixture varied from 0% to 40%. The effects of IT filler content on workability, curing temperature, mechanical properties, volume stability, and bond strength were investigated, accompanied by microstructural analysis. Experimental results reveal that the incorporation of IT filler ameliorates the fresh workability and shortens the setting time of epoxy mortar, whereas the compressive strength, flexural strength and interfacial bond strength exhibit an initial ascending followed by a descending trend with the increasing IT filler fraction. The optimal IT filler content is determined to be 20%. For fresh-state performance, the modified mortar delivers a flowability of 176.8 mm (+29.7% relative to EM-0) and a setting time of 127 min. In terms of hardened mechanical and bonding properties, the 28-day compressive strength, 28-day flexural strength and 7-day flexural bond strength reach 113.2 MPa (+17.2%), 42.5 MPa (+34.0%) and 9.1 MPa (+75.0%), respectively, in comparison with the reference specimen EM-0. Microscopic characterizations deliver indirect evidence that appropriate IT filler may refine internal pore-size distribution, densify matrix microstructure and suppress crack propagation. The failure mode changed from pure interfacial debonding to cohesive failure in the cement substrate. This work provides a green scheme for resource utilization of iron tailings in high-performance pavement repair materials.