Tunnel Mudstone Valorization from a Tunnel Project in Guangxi, China: Development of a Solidified Grouting Material for Karst Pile Foundation Cavity Treatment

Karst pile foundation cavity treatment requires grouting materials with suitable flowability, stability, strength, and cost-effectiveness, while large quantities of waste mudstone generated by tunnel excavation in Guangxi, China, also require sustainable valorization. In this study, tunnel-excavated mudstone from a tunnel project in Guangxi, China, was used as the primary raw material to develop a solidified grouting material for karst pile foundation cavity treatment. Uniform experimental design, stepwise nonlinear regression, response surface analysis, and multi-objective optimization were employed to evaluate the effects of key mix parameters and determine the optimal formulation. The results showed that the optimal slurry was obtained at a cementitious material-to-mudstone ratio of 0.16, an admixture-to-cementitious material ratio of 0.06, a water-to-solid ratio of 0.63, and the slag powder content-to-cementitious materials ratio of 0.34. In addition, the anti-dispersion performance improved by 87.78%, and compared with conventional cement-soil, C25 concrete, and C30 concrete, the CO2 emissions were reduced by 37%, 67.4%, and 68.6%, respectively, with the material cost being 73.8% lower than that of traditional cement mortar. These results indicate that the proposed material has promising engineering applicability and demonstrates significant economic and environmental benefits, as well as the valorization potential of tunnel-excavated mudstone.