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<p>Grouting materials are essential for controlling water inrush in underground engineering. While polyurethane/water glass (PU/WG) composites offer high early strength and elasticity, their use is limited by long curing times and high costs. To overcome these limitations, this study incorporates fly ash (FA), a coal-based solid waste, into PU/WG to develop eco-friendly FA/PU/WG composites (0–20 wt% FA). Systematic investigations revealed that FA addition reduced curing time by 37% (from 122 to 77&#xa0;s) through alkaline activation, concurrently facilitating the formation of a hydrated sodium aluminosilicate (N–A–S–H) gel network that enhanced interfacial crosslinking. The maximum reaction temperature initially increased (0–10 wt% FA) due to accelerated curing kinetics but decreased at higher FA contents&#xa0;(15–20 wt%) owing to the improved thermal conductivity of Al₂O₃ in FA combined with incomplete FA activation. Microstructural analysis (SEM/EDS) confirmed the reinforcing role of FA in microspheres; however, excessive FA incorporation (&gt; 15 wt%) led to a reduction in compressive strength, as limited Na<sub>2</sub>O content restricted FA activation. The optimal formulation (15%-FA/PU/WG) achieved a compressive strength of 67&#xa0;MPa, ultra-low permeability (1.24 × 10<sup>–25</sup>&#xa0;cm/s), and negligible heavy metal leaching. By repurposing waste FA as a functional filler, this work reduces material costs while providing a sustainable, high-performance solution for water-sealing applications, bridging industrial waste recycling with advanced engineering needs.</p> Graphical abstract <p></p>

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Sustainable high-performance grouting composites: fly ash reinforced polyurethane/water glass for rapid water sealing

  • 期刊论文

  • 发表日期：

    2025年9月8日

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  • Ming-Yi Li,
  • Wei-Xuan Wang,
  • Xu Li,
  • Lan Jia,
  • Feng-Bo Zhu,
  • Wen-Wen Yu

摘要

Grouting materials are essential for controlling water inrush in underground engineering. While polyurethane/water glass (PU/WG) composites offer high early strength and elasticity, their use is limited by long curing times and high costs. To overcome these limitations, this study incorporates fly ash (FA), a coal-based solid waste, into PU/WG to develop eco-friendly FA/PU/WG composites (0–20 wt% FA). Systematic investigations revealed that FA addition reduced curing time by 37% (from 122 to 77 s) through alkaline activation, concurrently facilitating the formation of a hydrated sodium aluminosilicate (N–A–S–H) gel network that enhanced interfacial crosslinking. The maximum reaction temperature initially increased (0–10 wt% FA) due to accelerated curing kinetics but decreased at higher FA contents (15–20 wt%) owing to the improved thermal conductivity of Al₂O₃ in FA combined with incomplete FA activation. Microstructural analysis (SEM/EDS) confirmed the reinforcing role of FA in microspheres; however, excessive FA incorporation (> 15 wt%) led to a reduction in compressive strength, as limited Na2O content restricted FA activation. The optimal formulation (15%-FA/PU/WG) achieved a compressive strength of 67 MPa, ultra-low permeability (1.24 × 10–25 cm/s), and negligible heavy metal leaching. By repurposing waste FA as a functional filler, this work reduces material costs while providing a sustainable, high-performance solution for water-sealing applications, bridging industrial waste recycling with advanced engineering needs.

Graphical abstract