To investigate the application of engineering geopolymer composites (EGC) in strengthening existing concrete components, a study was conducted using concrete as the substrate and EGC as the overlay. Two types of bonding interface treatments, chiseling and grooving, were employed, with various parameter levels specified for each treatment. Direct shear tests were performed to evaluate the bonding interface performance between EGC and concrete. According to the experimental data, it can be observed that as the interface roughness increases, the interface shear strength also increases. Although all bonded interfaces ultimately fail in EGC shear failure under ultimate shear states, different interface configurations exhibit distinct failure modes. The study further revealed that the load-displacement curves of the specimens exhibited similarities, characterized by ascending and descending segments. Specimens with higher interface roughness displayed a gentler descending curve after reaching the ultimate load. Using the experimental data, a nonlinear fitting method was employed to develop a shear strength calculation formula for the NC-EGC interface, which aligned well with the experimental results. Furthermore, the shear toughness of the NC-EGC bonding specimens was assessed through shear load-displacement curve analysis and a toughness evaluation approach tailored for fiber-reinforced concrete. The results showed that the toughness prior to the peak load was 139% and 234% of the C60 concrete control group, demonstrating the outstanding toughening ability of EGC.
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