The presence of joints in rock masses influences the structural integrity of geotechnical structures. A critical failure mode is shearing, thus making the shearing process of importance to understand. Historically, studies have been mainly executed on the basis of laboratory experiments, since full-scale in situ tests are seldom performed due to technical and economic considerations. Since each rock joint is unique by nature, the utilization of replicas is applied to carry out controlled experimental parameter studies. However, the manufacturing process of replicas introduces many sources of uncertainty. Therefore, in this work the influence of geometrical variations in replicas on the shear strength characteristics is evaluated, mutually as well as in relation to the mother rock specimen of the replicas. The joint surfaces were 3D scanned and the contact area of the joint was measured using pressure sensitive film before direct shear tests. Deviations in morphology were evaluated by surface comparisons between the joint surfaces of the mother rock and replicas. The initial matching of the joints was evaluated by calibrating the scanning data with respect to the contact area measurements. It could be visualized that geometrical deviations were caused by rock fragments coming off during mould production, positioning of the moulds and pores resulting from replica casting. These factors were found to influence the shear strength characteristics of the replicas. The influence of the deviations originating from morphology on the joint matching is demonstrated. In summary, it is shown that replicas with similar shear strength characteristics as rock can be manufactured, but even small deviations affect the characteristics, in particular the peak strength. Therefore, parameters relevant for geometrical quality assurance should be identified along with required value ranges. Selected introductory results on quantified parameters for geometrical quality assurance are presented, serving as a basis for continued work.

Since each rock joint is unique by nature, the utilization of replicas in direct shear testing is required to carry out experimental parameter studies. However, information about the ability of the replicas to simulate the shear mechanical behavior of the rock joint and their dispersion in direct shear testing is lacking. With the aim to facilitate generation of high-quality direct shear test data from replicas, a novel component in the testing procedure is introduced by presenting two parameters for geometric quality assurance. The parameters are derived from surface comparisons of three-dimensional (3D) scanning data of the rock joint and its replicas. The first parameter, sigma(mf), captures morphological deviations between the replica and the rock joint surfaces. sigma(mf) is derived as the standard deviation of the deviations between the coordinate points of the replica and the rock joint. Four sources of errors introduced in the replica manufacturing process employed in this study could be identified. These errors could be minimized, yielding replicas with sigma(mf) <= 0.06 mm. The second parameter is a vector, V-Hp100, which describes deviations with respect to the shear direction. It is the projection of the 100 mm long normal vector of the best-fit plane of the replica joint surface to the corresponding plane of the rock joint. vertical bar V-Hp100 vertical bar was found to be less than or equal to 0.36 mm in this study. Application of these two geometric quality assurance parameters demonstrates that it is possible to manufacture replicas with high geometric similarity to the rock joint. In a subsequent paper (part 2), sigma(mf) and V-Hp100 are incorporated in a novel quality assurance method, in which the parameters shall be evaluated prior to direct shear testing. Replicas having parameter values below established thresholds shall have a known and narrow dispersion and imitate the shear mechanical behavior of the rock joint.

Each rock joint is unique by nature which means that utilization of replicas in direct shear tests is required in experimental parameter studies. However, a method to acquire knowledge about the ability of the replicas to imitate the shear mechanical behavior of the rock joint and their dispersion in direct shear testing is lacking. In this study, a novel method is presented for geometric quality assurance of replicas. The aim is to facilitate generation of high-quality direct shear testing data as a prerequisite for reliable subsequent analyses of the results. In Part 1 of this study, two quality assurance parameters, sigma(mf) and V-Hp100, are derived and their usefulness for evaluation of geometric deviations, i.e. geometric reproducibility, is shown. In Part 2, the parameters are validated by showing a correlation between the parameters and the shear mechanical behavior, which qualifies the parameters for usage in the quality assurance method. Unique results from direct shear tests presenting comparisons between replicas and the rock joint show that replicas fulfilling proposed threshold values of sigma(mf) < 0.06 mm and vertical bar V-Hp100 vertical bar < 0.2 mm have a narrow dispersion and imitate the shear mechanical behavior of the rock joint in all aspects apart from having a slightly lower peak shear strength. The wear in these replicas, which have similar morphology as the rock joint, is in the same areas as in the rock joint. The wear is slightly larger in the rock joint and therefore the discrepancy in peak shear strength derives from differences in material properties, possibly from differences in toughness. It is shown by application of the suggested method that the quality assured replicas manufactured following the process employed in this study phenomenologically capture the shear strength characteristics, which makes them useful in parameter studies.

Applying accurate normal load to a specimen in direct shear tests under constant normal stiffness (CNS) is of importance for the quality of the resulting data, which in turn influences the conclusions. However, deficiencies in the test system give rise to a normal stiffness, here designated as system normal stiffness, which results in deviations between the intended and actual applied normal loads. Aiming to reduce these deviations, this paper presents the effective normal stiffness approach applicable to closed-loop control systems. Validation through direct shear tests indicates a clear influence of the system normal stiffness on the applied normal load (13% for the test system used in this work). The ability of the approach to compensate for this influence is confirmed herein. Moreover, it is demonstrated that the differences between the measured and the nominal normal displacements are established by the normal load increment divided by the system normal stiffness. This further demonstrates the existence of the system normal stiffness. To employ the effective normal stiffness approach, the intended normal stiffness (user defined) and the system normal stiffness must be known. The latter is determined from a calibration curve based on normal loading tests using a stiff test dummy. Finally, a procedure is presented to estimate errors originating from the application of an approximate representation of the system normal stiffness. The approach is shown to effectively reduce the deviations between intended normal loads and the actual applied normal loads.

Experiments at constant normal stiffness (CNS) are normally carried out to understand underground shear processes of rock joints. However, in many test setups the available space around the joint is limited implying it is not possible to measure the dilatancy directly over the joint. Therefore, the displacement transducers must be in locations where the risk is that additional displacements originating from deficiencies in the test system will be measured causing too low normal loads to be applied. Herein, this issue is investigated in a new 5 MN direct shear test setup. The system normal stiffness was found to be about 11 300 kN/mm derived from normal loading up to 4.5 MN using a steel specimen. The direct shear testing performance under the CNS configuration was evaluated using the steel specimen, which had a joint with a known angle of inclination. The normal load error at 3.9 MN (28 MPa) was 11%, but by application of the effective normal stiffness approach using the system normal stiffness as input the error basically could be eliminated. The results demonstrate the robustness of the setup designed for joint areas up to 400 × 600 mm with normal and shear loads up to 5 MN.