Study on the Multi-Factor Coupling Mechanism Affecting the Permeability of Remolded Clay

To address the critical challenges of geological hazards, such as water and mud inrush, encountered during the construction of deep-buried tunnels in China, this study investigates the hydraulic properties of remolded mud-infill materials. A multi-scale approach, integrating indoor variable-head permeability tests with scanning electron microscopy (SEM), was employed to characterize the evolutionary patterns of the permeability coefficient (k). Specifically, the research evaluates the independent influences of moisture content, dry density, and confining pressure, alongside the synergistic coupling between dry density and hydration state. The results demonstrate the following: Under independent variable conditions, k exhibits a monotonic decline with increasing dry density and confining pressure while showing a positive correlation with moisture content, with the sensitivity varying significantly across different parameter regimes; under coupled effects, the permeability in both low- and high-moisture ranges manifests a distinct “increase–decrease–increase” fluctuation as dry density rises, reaching a local peak at 2.20 g/cm3. Notably, a relative minimum k (6.12 × 10−7 cm/s) is achieved at the optimum moisture content (5.8%); micro-mechanistic analysis reveals that low-moisture samples are characterized by randomized angular particles and well-developed interconnected macropore networks, facilitating higher k values. Conversely, high-moisture samples exhibit preferential plate-like stacking dominated by occluded micropores, resulting in a substantial reduction in hydraulic conductivity. This study elucidates the multi-factor coupling mechanism governing the seepage behavior of remolded mud, providing essential theoretical benchmarks for the prediction and mitigation of water–mud outburst disasters in deep underground engineering, thereby ensuring the structural stability and operational safety of tunnel projects.