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

IF 3.9 3区 材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY
Ming-Yi Li, Wei-Xuan Wang, Xu Li, Lan Jia, Feng-Bo Zhu, Wen-Wen Yu
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Abstract

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

Abstract Image

可持续高性能注浆复合材料:粉煤灰增强聚氨酯/水玻璃快速止水
注浆材料是控制地下工程突水的必要材料。虽然聚氨酯/水玻璃(PU/WG)复合材料具有很高的早期强度和弹性,但其使用受到固化时间长和成本高的限制。为了克服这些限制,本研究将煤基固体废物粉煤灰(FA)掺入PU/WG中,以开发环保型FA/PU/WG复合材料(0-20 wt% FA)。系统研究表明,FA的加入通过碱性活化使固化时间缩短了37%(从122秒缩短到77秒),同时促进了水合铝硅酸钠(N-A-S-H)凝胶网络的形成,增强了界面交联。由于固化动力学加速,最高反应温度最初升高(0-10 wt% FA),但在FA含量较高时(15-20 wt% FA),由于FA中Al₂O₃的导热性提高以及FA的不完全活化,最高反应温度降低。微观结构分析(SEM/EDS)证实了FA在微球中的补强作用;然而,过量的FA掺入(> 15 wt%)导致抗压强度降低,因为有限的Na2O含量限制了FA的活化。最佳配方(15%-FA/PU/WG)抗压强度为67 MPa,渗透性极低(1.24 × 10-25 cm/s),重金属浸出可忽略。通过将废弃FA重新利用为功能性填料,这项工作降低了材料成本,同时为水封应用提供了可持续的高性能解决方案,将工业废物回收与先进的工程需求联系起来。图形抽象
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来源期刊
Journal of Materials Science
Journal of Materials Science 工程技术-材料科学:综合
CiteScore
7.90
自引率
4.40%
发文量
1297
审稿时长
2.4 months
期刊介绍: The Journal of Materials Science publishes reviews, full-length papers, and short Communications recording original research results on, or techniques for studying the relationship between structure, properties, and uses of materials. The subjects are seen from international and interdisciplinary perspectives covering areas including metals, ceramics, glasses, polymers, electrical materials, composite materials, fibers, nanostructured materials, nanocomposites, and biological and biomedical materials. The Journal of Materials Science is now firmly established as the leading source of primary communication for scientists investigating the structure and properties of all engineering materials.
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