Nano-SiO2-reinforced epoxy resin gel mortar (NERM) serves as an essential material for repairing and strengthening defective structures in civil engineering. This study developed a hybrid fiber-reinforced NERM (HF-NERM) by incorporating PVA–steel fiber, aiming to achieve superior mechanical properties, toughness, and bonding performance. This study systematically investigates the workability, mechanical properties, toughness, and bonding characteristics of HF-NERM, as well as their enhancement mechanisms characterized using scanning electron microscopy (SEM). Experimental results indicate that the slump of HF-NERM decreased significantly with increasing hybrid fiber content, and the regression coefficient of PVA fiber on slump was −86.7, while that of steel fiber was −4.5. The addition of hybrid fibers generally enhanced the mechanical properties. The optimal combination was 0.9% PVA fiber and 1.2% steel fiber, at which the flexural strength reached 11.56 MPa with an increase of 32.57%, splitting tensile strength reached 4.42 MPa with an increase of 20.1%, and interfacial bonding strength was improved by 9.8%. With the exception of splitting tensile strength, most mechanical properties initially increased and then decreased with increasing hybrid fiber content, indicating an optimal dosage. The hybrid fibers also enhanced the flexural toughness of HF-NERM; the toughness indices I5, I10 and I20 were increased by 20.99%, 24.12% and 65.83%, respectively, and the residual strength factors R5,10 and R10,20 were increased by 26.8% and 160.8%. The hybrid fibers also enhanced the flexural toughness of HF-NERM. Mechanistically, PVA fibers primarily contributed to preventing the development of micro-cracks, while steel fibers were the main contributors to resisting macro-cracks. SEM observations demonstrated that the failure modes of PVA fibers involved synergistic mechanisms, while those of steel fibers were relatively singular. Related enhancement mechanisms were discussed based on the experimental results. Finally, the results demonstrate that NERM could be effectively strengthened by adding an appropriate content of hybrid fibers. This study’s novelty lies in quantifying the individual and synergistic effects of PVA–steel fibers in the NERM system, establishing optimal dosage parameters, and revealing matrix–fiber interaction mechanisms specific to epoxy-based composites. The findings provide a reliable material design basis for high-performance repair mortars and offer practical guidance for extending the service life of aging civil engineering structures.
Zhang et al. (2026) studied this question.