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This study presents experimental and numerical studies of the initiation and propagation of interface debonding between the substrate and thin-bonded cement-based overlay under fatigue testing. The overlay material is mortar incorporating amorphous metallic fibres (30 kg/m) and/or rubber aggregates (30%), while the substrate is a plain mortar. Uniaxial tensile tests were carried out on overlay materials and substrate-overlay interface to obtain a residual normal stress-crack opening relationship ( σ -w law) and residual normal stress and substrate-overlay interface debonding relation respectively. Three-point bending fatigue tests were carried out on the composite beam to analyse the structural behaviour of repaired beam. The propagation of debonding along the substrate-overlay interface was monitored by using the Digital 3D Image Correlation (DIC) technique. Three-point bending fatigue test was modelled by finite element method (FEM) using CAST3M, developed by French Atomic Energy Commission. Direct tension test results show reduction in tensile strength and improvement in strain capacity (1.5 times of control mortar) for rubberised mortars. For fibre-reinforced mortars, post-peak residual tensile strength is significantly enhanced. Rubberised fibre-reinforced mortars show positive synergetic effects both in the improvement of residual post-peak strength and strain capacity (3.5 times than control mortar). Results show that the rubberised fibre-reinforced thin-bonded cement-based overlay proved to be very effective in restraining crack opening, by transferring stresses through the crack, and enhancing the fatigue resistance of repair system, by limiting interface debonding propagation upto 50%. Experimental results of composite beams are in good agreement with modelling results.

Debonding of rubberised fibre-reinforced cement-based repairs under fatigue loading: experimental study and numerical modelling