Performance Analysis and Mix Proportion Optimization of Coal Gangue Concrete Under Sulfate Dry–Wet Cycling Conditions

The performance degradation of concrete structures in underground water sumps within the Ordos mining area has become increasingly prominent due to environmental factors, particularly the sulfate-induced dry–wet cycles. These conditions lead to the development of cracks, spalling, and structural instability, which poses significant safety risks. This issue must be addressed with consideration of the regional hydrogeological characteristics and the current requirements for safe, sustainable, and environmentally responsible coal mining practices. The study investigates the concrete employed in the underground central water reservoir of Bulianta Coal Mine in the Ordos mining area. A novel approach is proposed for developing sulfate-resistant concrete capable of withstanding dry–wet cyclic conditions in underground environments through the utilization of coal gangue sourced from the same mining operation. Considering concrete performance, cost-effectiveness, and coal gangue utilization, a laboratory mix optimization study was conducted and the optimal mixture proportion was determined to be a 60% gangue content, a 30% fly ash content, a water–binder ratio of 0.38, which produced concrete with a compressive strength of 31 MPa. Sulfate resistance tests were conducted on the optimal mixture of dry–wet cycle-resistant concrete. The effect of different dry–wet cycle counts on the compressive strength of the coal gangue concrete was investigated, and the evolution patterns of the ascending segment shape coefficient a and descending segment shape coefficient b under sulfate-induced dry–wet cycling were analyzed. Combining the Guo Zhenhai concrete constitutive model, a concrete constitutive model suitable for the dry–wet cycle conditions of sulfate was established. Based on the proposed constitutive model, the uniaxial compressive mechanical behavior of coal gangue concrete subjected to sulfate attack was investigated through numerical simulations using the Abaqus (2020) software. The simulation results are basically consistent with the laboratory results, which proves the applicability of the constitutive model and confirms the performance of the optimal proportioning scheme for preparing sulfate-resistant dry–wet cycle concrete using coal gangue from underground mines. This study provides a new type of concrete for similar underground conditions in this mining area and offers a new approach for the comprehensive utilization of coal gangue.