Machine Learning-Assisted Multi-Objective Optimization of Surface Pretreated Coal Gangue Lightweight Shotcrete

The large-scale accumulation of coal gangue has created increasing environmental pressure, while its use as aggregate in cementitious materials remains limited by its high water absorption, porous structure and unstable mechanical performance. This study develops a machine learning-assisted multi-objective optimization framework for lightweight shotcrete incorporating surface-pretreated coal gangue aggregates and polyvinyl alcohol fibres. Two pretreatment methods—namely, silica-fume slurry coating (CGACM) and dry adsorption activation (CGACD)—were applied to improve the aggregate surface characteristics. Experimental data on compressive strength, splitting strength and density were used to train backpropagation neural networks and support vector machine and random forest models, with hyperparameters optimized by the Beetle Antennae Search algorithm. The trained models were then coupled with a multi-objective optimization procedure to balance mechanical performance, density, material cost and CO2 emissions. The results show that surface pretreatment can improve the performance of coal gangue lightweight shotcrete, while the proposed optimization framework can identify mixture designs with balanced strength, reduced density and improved economic and environmental performance. Compared with untreated or non-optimized mixtures, the optimized surface-pretreated mixtures achieved a more favorable trade-off among mechanical, cost and carbon-emission objectives. This study provides a data-driven approach for the sustainable design and practical utilization of coal gangue in lightweight shotcrete.