Objective Studying the shear characteristics of the interface between granite residual soil and concrete is crucial for ensuring the safety of geotechnical engineering applications, including pile foundations, anchor rods, and underground pipelines. At present, the shear characteristics of the interface are primarily influenced by the water content of the soil and the roughness of the concrete surface. This study investigates the effects of these two factors on the shear characteristics through experimental and numerical analysis. Methods Based on the standard structural surface roughness curve, a three-dimensional model representing surfaces with different roughness levels was established. TPU molds with varying roughness values were produced using 3D printing technology, and concrete test blocks exhibiting different surface roughness characteristics were cast. Indoor large-scale direct shear tests were conducted under four water content levels (14%, 19%, 24%, and 29%) shear stress displacement curve, shear strength, and vertical displacement were analyzed. Finally, discrete element software was employed to investigate meso-mechanical characteristics, including porosity, force chain distribution, and fabric anisotropy, of granite residual soil during the shearing process. Results and Discussions The test results indicated that the interfacial shear strength initially increased and decreased with increasing water content. At a water content of 19%, the maximum interfacial shear strength and interfacial cohesion were achieved, with values of 82.4 kPa and 30.17 kPa, respectively, under a normal stress of 100 kPa. Water content exerted a pronounced influence on the stress-strain behavior of the interface. At lower water content levels ranging from 14% to 19%, shear softening behavior was observed, whereas higher water content levels from 24% to 29% exhibited shear hardening behavior. At a water content of 14%, the strains corresponding to peak interface shear stress were 3.26%, 3.84%, and 3.96 % under normal stresses of 100 kPa, 200 kPa, and 300 kPa, respectively, indicating enhanced shear ductility with increasing normal stress. As the concrete roughness coefficient increased, the interface shear strength increased gradually; however, once the critical roughness value was reached, further increases in roughness did not result in additional shear strength enhancement. When the concrete surface was relatively smooth, the interface shear strength mainly originated from frictional resistance between the soil and concrete, and the shear failure surface was located at the interface. When the concrete surface became rougher, grooves on the surface interlocked with soil particles, generating a biting effect that increased the interface shear strength and caused the shear failure surface to shift from the interface into the soil, forming a localized shear band. With further increases in roughness beyond the critical value, additional soil particles filled the surface grooves, which reduced the effective roughness of the concrete surface and led to a marginal occlusion effect. Therefore, the shear failure surface no longer propagated deeper into the soil and even exhibited slight regression, resulting in no further increase in interface shear strength. Numerical simulation results further demonstrated that the particle porosity within the upper 5 cm range of the sample increased during shearing, whereas the porosity in the remaining regions showed an opposite trend. The influence of porosity on particle behavior gradually decreased with increasing distance from the interface. In addition, the principal anisotropy directions of both normal and tangential contact forces deflected consistently with the shear direction. Conclusions A critical roughness value was identified at the soil‒concrete interface. Before reaching this critical roughness, the shear strength, interfacial cohesion, and internal friction angle of the interface increased with increasing roughness. However, once this critical value (JRC equals to 12.8) was exceeded, further increases in these parameters ceased, and a stable state was reached. Simulation results indicated pronounced anisotropy in both normal and tangential contact forces, with the principal anisotropic direction aligned with the direction of maximum compressive stress, enhancing resistance to shear deformation. In practical foundation engineering applications, the water content of foundation soil can be appropriately controlled based on experimental findings. In addition, the surface morphology of concrete can be designed with reference to the critical roughness value, improving interface shear resistance.
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