In deep coal mining, grouting reinforcement and water blockage are the most effective means for reinforcing the rock mass of extremely broken coal. However, traditional cement grouting materials are not suitable for use in complex strata because of their insufficient early mechanical strength and slow setting time. This study innovatively proposes using alkali-activated grouting material to compensate for the shortcomings of traditional grouting materials and strengthen the reinforcement of extremely unstable broken coal and rock mass. The alkali-activated grouting material was prepared using slag as raw material combined with sodium hydroxide and liquid sodium silicate activation. The compressive strength of specimens cured for 1 d, 3 d, and 28 d was regularly measured and the condensation behavior was analyzed. Using X-ray diffraction and scanning electron microscopy, formation behavior of mineral crystals and microstructure characteristics were further analyzed. The results showed that alkali-activated slag grouting material features prompt and high strength and offers the advantages of rapid setting and adjustable setting time. With an increase in sodium hydroxide content, the compressive strength first increased (maximum increase was 21.1%) and then decreased, while the setting time continued to shorten. With an increase in liquid sodium silicate level, the compressive strength increased significantly (and remained unchanged, maximum increase was 35.9%), while the setting time decreased significantly (and remained unchanged). X-ray diffraction analysis identified the formation of aluminosilicate minerals as the main reason for the excellent mechanical properties and accelerated coagulation rate.

In this study, coralline-activated materials were prepared using ball-milled coral powder as cementitious material and coral sand as fine aggregate. XRF (X-ray fluorescence) and chemical dissolution tests were carried out to determine the content and reactivity of various elements in coral powder. The compressive strength of the developed composites was evaluated at different ages, and the formation and transformation of mineral crystals in coralline-activated samples were further analyzed by XRD (X-ray diffractometer). The results show that the calcium content in coral powder was as high as 89.5% (loss on ignition). However, only 56% of the active calcium could participate in the polymerization reaction. The silicon and aluminum content was too low, and the slag addition could improve the deficiency of silicon and aluminum in coral powder. With the increase in slag content (from 0% to 50%), the compressive strength of the composites increases significantly. Nevertheless, the enhancement is not pronounced when the slag content exceeds 50%. The increase in slag amount can stimulate the transformation of calcium minerals, e.g., aragonite and calcite, into hydrated calcium silicate and calcium aluminosilicate gels, which significantly enhances the resulting compressive strength.

To further enhance the compressive strength of alkali-activated materials and reveal their condensation behavior, the reactivity of alkali-activated slag materials was enhanced through the addition of different kinds and proportions of sodium silicate. The mechanical properties of the specimens were observed regularly and the condensation behavior was further analyzed. The results showed that both solid and liquid sodium silicate could significantly improve the compressive strength. The maximum increase in compressive strength was 123.7%, while the initial and final setting times were significantly shortened to 9 min. When solid sodium silicate content increased from 5% to 15%, the compressive strength first increased to 34.6 MPa and then decreased to 28.6 MPa, indicating that 10% was the optimum solid sodium silicate content. The large amount of crystallized solid sodium silicate in the specimen led to the decrease in mechanical properties. When liquid sodium silicate content increased from 5% to 15%, the compressive strength first increased to 52.8 MPa and then tended to be stable, implying that 10% was the optimum content. This shows that its reinforcement effect has a maximum limit. The activation effect of liquid sodium silicate was better than that of solid.

To resolve problems caused by the accumulation of flue gas desulfurization gypsum (FGDG) in the environment, a polymer material was prepared using FGDG, granulated blast furnace slag (GBFS), fly ash (FA), and solid sodium silicate (SSS). The compressive strength of these polymer specimens cured for 3, 28, and 60 d was regularly measured, and their condensation behavior was analyzed. Both the formation behavior of mineral crystals and microstructure characteristics were analyzed further using X-ray diffraction and scanning electron microscopy. The compressive strength of pure FGDG polymer specimen (whose strength is generated by particle condensation crystallization) is insufficient and the condensation is slow. The addition of appropriate amounts of GBFS, FA, and SSS can continuously and considerably improve the compressive strength and shorten the setting time. The optimal proportions of FGDG, GBFS, and FA are 50%, 20%, and 30%, respectively, with the SSS addition amount of 20 g. The incorporation of GBFS, FA, and SSS can promote the polymerization of calcium, silicon, and aluminum in FGDG to form silicate and aluminosilicate minerals. Their formation is the main reason for the increased compressive strength and accelerated coagulation.