Sand–Steel Interface Performance Using Fibre Reinforcement: Experimental and Physics-Guided Artificial Intelligence Prediction

Soil–steel interface shear governs load transfer and long-term serviceability in piles, retaining systems, and buried infrastructure; yet the large-displacement interface mechanics of fibre-reinforced sands remain poorly resolved, limiting sustainable design. This study couples large-displacement ring-shear testing with physics-guided hybrid AI to quantify and predict the peak and residual resistance of sand–polypropylene fibre mixtures sliding on smooth and rough steel. Two quartz sands with contrasting particle morphology were tested under 25–200 kPa normal stress and 0–1.0% fibre content, producing a design-oriented database that captures post-peak evolution and residual states. The experiments reveal a strongly nonlinear reinforcement law: an optimum fibre range enhances dilation, stabilises the shear band, suppresses post-peak softening, and increases residual strength, whereas excessive fibres disrupt the granular skeleton and reduce mobilisation efficiency. Roughness and confinement act as amplifiers, intensifying fibre-driven dilation and asperity interlock. To translate mechanisms into prediction, three strategies were benchmarked: a deep neural network (DNN), the Physics-Guided Neural Additive Model (PG-NAM++), and the physics-anchored Residual-DNN that learns only the correction to a mechanical baseline. Residual-DNN achieved the tightest agreement and the highest physical consistency for both peak and residual strength, enabling robust parameter selection with reduced uncertainty and overdesign. The combined experimental–AI framework advances the United Nations Sustainable Development Goals (SDGs) by supporting SDG 9 through resilient, innovation-led infrastructure design and contributing to SDG 12 by enabling optimised (rather than maximal) use and reuse of reinforcement materials within circular ground-improvement practice.