Various metal ions in acid mine drainage (AMD) cause environmental pollution. Due to the unique advantages of heavy metal treatment and gelling properties, previous concretes incorporating red mud have attracted extensive attention in AMD passive treatment, which utilises naturally occurring chemicals to cleanse contaminated mine waters with low operating costs. This study aims to develop red mud–based geopolymer pervious concrete as an eco–friendly method to remove heavy metals in AMD. Compared with raw pervious concrete, red mud–based geopolymer pervious concrete improves the purification efficiency of heavy metals. The high rate of acid reduction and metal removal by the geopolymer is attributed to the dissolution of portlandite in red mud. Precipitation of metal hydroxides seems to be the dominant metal removal mechanism. Under optimal conditions (influent pH = 4.0 and the hydraulic retention time = 24 h), red mud–based geopolymer pervious concrete could completely remove Cu(II), Mn(II), Cd(II) and Zn(II) by up to 10 mg/L, 10 mg/L, 1.6 mg/L and 16 mg/L, respectively. When the influent pH is 2.5, the hydrolysis of Fe(III) released from red mud increases the consumption of OH⁻. Moreover, when the influent pH is 4.0, the precipitation of CaSO₄ promotes the dissolution of portlandite and metal removal. Therefore, red mud has demonstrated feasibility in the manufacturing of geopolymer–based pervious concrete for purification AMD.

Interlayer bond strength is critical for ensuring the safety and durability of 3D-printed concrete (3DPC) structures. However, there remains a lack of real-time prediction methods addressing interlayer performance under the combined effects of interval time and environmental factors during the in situ printing process. To address this issue, this study conducted experiments considering various printing interval times and environmental conditions, incorporating monitoring of dielectric constant and water evaporation, alongside interlayer splitting tensile tests. By integrating the SHAP interpretability algorithm with nonlinear regression analysis, the results indicate that the printing interval time is the dominant factor inducing interlayer strength decay (with a contribution rate of 68.6%), while relative humidity emerges as the primary environmental variable (with a contribution rate of 21.3%). Mechanism analysis reveals that prolonged printing intervals intensify the hydration of the lower deposited layer, leading to reduced interfacial moisture content and loss of plasticity. Furthermore, environmental evaporation significantly regulates this process, with high-humidity environments notably mitigating the moisture loss and strength reduction caused by time delays. Based on the correlation mechanism between moisture and strength, a dimensionless general prediction model for 3DPC interlayer strength was established, incorporating printing interval time and an evaporation index (goodness of fit, R² = 0.96). Consequently, a digital twin quality inversion scheme based on companion specimen monitoring and printing timestamps was proposed. This study quantifies the intrinsic relationships among printing interval time, environmental conditions, and interlayer strength, offering a novel approach for determining the construction window and achieving non-destructive quality prediction for 3DPC in complex environments.

The interlayer pores of 3D-printed concrete (3DPC) significantly weaken its macroscopic mechanical properties. In this study, the phase-field cohesive zone model (PF-CZM) is employed as a numerical tool to systematically investigate the weakening mechanisms and crack evolution behavior associated with pore characteristics, including pore size, morphology, spatial orientation, and arrangement, through single-factor numerical simulations with different pore numbers. The results demonstrate that the degradation induced by a single pore is controlled by its effective projection length in the direction perpendicular to the principal tensile stress, with horizontal flat pores being the most detrimental under the same porosity. In the multi-pore system, the connection angle between pores, rather than their spacing, is the key factor determining structural degradation, and a horizontal collinear arrangement is prone to triggering brittle fracture. Furthermore, locally aggregated small pores can form combined defects, whose strength-weakening effect surpasses that of isolated large pores, thereby triggering crack path competition and leading to asymmetrical structural failure. This study reveals the fracture mechanisms driven by complex pore configurations and provides a reference for strength prediction of 3DPC.