Coal gangue is one of the industrial solid wastes that may harm the human body through the ecosystem for a long time. Using coal gangue in geopolymer preparation can effectively reduce cement output and meet the sustainability requirements. In this paper, the physical and chemical characteristics, including the heavy metal content, of coal gangue from different producing areas are described. Then, the mechanism of physical activation (mechanical and thermal activation), chemical activation, and compound activation of coal gangue are illustrated. The machinability, as well as the mechanical, microscopic, and toxicity consolidation properties of geopolymers prepared from coal gangue, are summarized and analyzed. The results indicate that the coal gangue geopolymers can have higher mobility and mechanical strength than cement-based composites by adjusting high calcium element material, alkali activator content, Na₂SiO₃ modulus, and curing condition. After physical activation, coal gangue is used in geopolymer preparation with a chemical activator (alkali excitation agent), which effectively forms a three-dimensional silicon aluminate polymer network. The pore structure is dense, the physical fixation and chemical bonding are strengthened, and the solidification and adsorption of heavy metal ions are improved. Further, it can also be applied to solidifying radioactive waste, which is following the future development direction.

Coal gangue is a kind of industrial solid waste with serious ecological and environmental implications. Producing concrete with coal gangue aggregate is one of the green sustainable development requirements. This paper reviews the properties and preparation methods of Chinese gangue aggregate, studies the influence of gangue aggregate on concrete properties and the prediction model of gangue concrete, and summarizes the influence of modified materials on gangue concrete. The studies analyzed in this review show that different treatments influence the performance of coal gangue aggregate concrete. With the increase in the replacement ratio of coal gangue aggregate in concrete, the concrete workability and mechanical performance are reduced. Furthermore, the pore structure changes lead to decreased porosity, greatly affecting the durability. Coal gangue is not recommended for producing high-grade concretes. Nevertheless, pore structure can be improved by adding mineral admixtures, fibers, and admixtures to the coal gangue concrete. Hence, the working properties, mechanical properties, and durability of the concrete can be improved effectively, ensuring that coal gangue concrete meets engineering design requirements. Adding modified materials to coal gangue concrete is a viable future development direction.

Due to the high water absorption of coal gangue aggregate, concrete prepared with a high content of this material exhibits a significantly reduced service life under freeze–thaw conditions. This study evaluates the frost resistance of gel-enhanced coal gangue aggregate concrete modified by incorporating nano-SiO₂ and polypropylene fibre (PPF) to generate more C-S-H gel and form a dense structure with different dosages of air-entraining agent (0, 0.004%, 0.008%, 0.012%, and 0.016%). The research results show that when the admixture content is 0.012%, the concrete still exhibits excellent frost resistance after 100 freeze–thaw cycles. The mass loss is only 4.7%, compressive strength loss is 37%, and dynamic elastic modulus loss is 39%, while the specimen maintains the best apparent integrity. In addition, the capillary water absorption rate, initial capillary water absorption rate, and cumulative water absorption all reach their lowest values under this condition, indicating optimal frost resistance performance. Finally, through regression analysis, a highly accurate predictive model for capillary water absorption was established, providing a theoretical basis for further research on the durability and frost resistance of coal gangue aggregate concrete.