As a solid waste produced by coal combustion, fly ash will cause serious environmental pollution. However, it can be considered as a sustainable and renewable resource to replace partial cement in grouting materials. Fly ash grouting materials re-cement the broken rock mass and improve the mechanical properties of the original structure. It can reinforce the broken surrounding rock of mine roadway. The utilization of fly ash also reduces environmental pollution. Therefore, this paper establishes a new material mixture ratio optimization model to meet the requirement of material property through combining the methods of experimental design and numerical analysis. Based on the Box–Behnken design with 3 factors and 3 levels, a mathematical model is constructed to fit the nonlinear multiple regression functions between material properties and raw materials ratios. The influence of raw materials is analyzed on material properties (the material’s 7-day uniaxial compressive strength, initial setting time, and slurry viscosity). Then, 80 Pareto solutions are obtained through NASG-II algorithm which takes the regression functions as the objective functions for multi-objective optimization of the grouting material ratio. Finally, the best ratio solution of water-cement ratio—0.71, silica fume content—1.73%, and sodium silicate content—2.61% is obtained through the NNRP-TOPSIS method.

This paper aims to study the porous structure and the mechanical properties of fly-ash-based light-weighted porous geopolymer (FBLPG), exploring the feasibility of using it in roof-adaptive end filling technology based on its in-situ foaming characteristics and plastic yielding performance. A porous structure model of FBLPG during both the slurry and solid period was established to study their influence factor. In addition, this study also built a planar structure model in the shape of a honeycomb with bore walls, proving that the bore walls possess the characteristics of isotropic force. FBLPG shows a peculiar plastic yielding performance in the experiment where its stress stays stable with the gradual increase of the deformation, which can guarantee the stability of a filling body under the cycled load from the roof. At the same time, the in-situ foaming process combined with the unique filling technique can make the FBLPG filling body fully in contact with the irregular roof. This roof-adaptive end filling technology makes it a successful application in plugging the 1305 working face, which avoids problems of the low tight-connection ratio and secondary air-leakage channel resulted from the traditional filling technology, effectively improving coal production in terms of safety and high efficiency.