The limitations of conventional reinforced concrete (RC) lining segments in complex geological and fire-prone environments have driven the demand for more durable and fire-resilient materials in shield tunnel construction. Ultra-high-performance concrete (UHPC) offers outstanding strength and durability but is vulnerable to explosive spalling and rapid strength degradation at elevated temperatures. This study develops a multi-scale fiber-reinforced ultra-high-performance concrete (MSFUHPC) incorporating steel, polyethylene, and carbon fibers, together with fly ash cenospheres (CE), aiming to enhance thermal stability, suppress spalling, and reduce thermal degradation through their synergistic effects. Comparative experiments investigate the spalling behavior and mechanical performance of MSFUHPC segments with and without rebars, under both ambient conditions and hydrocarbon (HC) fire conditions. Results show that MSFUHPC segments exhibit superior fire resistance, reduced spalling depth, and improved load-bearing capacity compared with conventional concrete. CE-containing segments exhibit a maximum spalling depth of only around 5 mm and retain up to 2.9 times the post-fire load-bearing capacity of RC linings. Rebars further mitigate spalling and enhance post-fire ductility by improving heat dissipation and stress redistribution, and their partial strength recovery after cooling contributes to residual capacity retention. Overall, MSFUHPC demonstrates excellent mechanical stability, spalling resistance, and post-fire recovery, offering a practical and fire-resilient material solution for next-generation shield tunnel linings.
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