粉煤灰掺量对超细水泥复合注浆材料性能调控及加固机制的影响

Effect of fly ash content on performance regulation and reinforcement mechanism of ultrafine cement composite grouting materials

  • 摘要: 为解决深部软岩开采中水泥基注浆材料力学性能不足、工业固废利用率低等问题,在多组分外加剂(速凝剂、减水剂和膨胀剂)耦合作用下,研发一种新型高性能粉煤灰(FA)改性超细水泥(UC)复合注浆材料(FASC). 利用宏观性能测试、XRD、FTIR、SEM与TG微观分析,系统研究FASC浆体可注性、凝结行为、力学强度及微观结构随FA掺量演变规律. 研究结果表明,FA掺入会延缓FASC凝结时间,增大流动度,降低泌水率并改善浆液稳定性;抗压、抗折强度随FA掺量呈先增大后减小趋势,5% FA掺量下FASC力学性能最优,28 d抗压强度(39.8 MPa)较基准提升2.6%,1 d、28 d抗折强度则分别提升12.6%、8.7%. 微观机理显示,5% FA可通过FA的火山灰效应消耗Ca(OH)2,促进二次C–S–H凝胶生成,优化孔隙结构,实现基体密实化. 砂岩碎石胶结加固试验表明,5% FA可促进超细水泥基胶结体抗压强度与弹性模量分别提升13.1%和9.2%,具有增强的形变恢复能力,这主要归为FA对FASC的“物理填充–化学胶结–裂纹钝化”协同耦合效应.

     

    Abstract: A novel fly ash (FA) modified ultrafine cement composite grouting material (FASC) was developed under the coupling effect of multicomponent admixtures, including an accelerator, a polycarboxylate superplasticizer, and an expansive agent, to address deficiencies in the mechanical performance and low industrial solid waste utilization of conventional cement-based grouting materials in deep soft rock mining. The water-to-cement ratio was fixed at 0.4, and the mass fraction of FA content was varied from 0% to 20 % (designated as S1–S5). All experiments were conducted at (20±2) °C. The workability parameters—setting time, fluidity, bleeding rate, and expansion—were measured according to Chinese standards. Mechanical properties, including compressive and flexural strengths, were evaluated at 1, 3, 7, and 28 d. Microstructural evolution was characterized by X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy with deconvolution fitting, scanning electron microscopy (SEM), and thermogravimetry (TG) analyses on samples cured for 7 and 28 d. Sandstone gravel cementation tests were also performed using 0% and 5% FA formulations to assess the practical reinforcement performance under uniaxial compression. The results indicated that increasing FA content prolonged both initial and final setting times, enhanced fluidity, and significantly reduced the bleeding rate. For the optimal 5% FA sample (S2), the initial and final setting times increased by 118.4% and 95.2%, respectively, compared to the control (S1), while the bleeding rate decreased by 25%. Compressive and flexural strengths first increased and then decreased with rising FA content. At 5% FA, the 28 d compressive strength reached 39.8 MPa, which was 2.6% higher than that of S1. The 1 and 28 d flexural strengths increased by 12.6% and 8.7%, respectively. Further increases in FA content by at least 10% led to gradual strength reduction, with S5 (20% FA) showing a 26.5% decrease in 28 d compressive strength relative to S1. The expansion ratio of hardened FASC peaked at 5% FA (+0.9% vs. S1). Microstructural analyses provided mechanistic insights. XRD patterns revealed that the principal hydration products were ettringite, C–S–H gel, and Ca(OH)2. As the FA content increased up to 15%, the C–S–H peak intensified while the Ca(OH)2 peak weakened, confirming pozzolanic consumption of Ca(OH)2 to form additional C–S–H. FTIR deconvolution fitting in the 800–1300 cm–1 region showed that the peak area of Q2–3 (medium-to-low polymerized C–S–H) increased by 305%–424% for FA-containing samples relative to S1, indicating that FA promoted C–S–H formation. SEM observations demonstrated that the 5% FA sample possessed a dense microstructure with a well-defined C–S–H gel layer at the FA interface, effectively filling micropores. In contrast, higher FA content (≥10%) introduced unreacted glass beads and microcracks. Energy dispersive X-ray spectroscopy analysis revealed a decrease in Ca/Si atomic ratio from 4.44 (S1) to 2.14 (S2), confirming secondary hydration. TG/derivative thermogravimetry curves further showed that the 5% FA sample exhibited higher mass loss in the 0–150 °C range and stronger dehydration peaks at 150 °C and 400 °C, corresponding to increased C–S–H and ettringite, while the Ca(OH)2 decomposition peak at 420 °C was weaker, indicating enhanced pozzolanic consumption. Sandstone gravel cementation tests confirmed the optimal performance at 5% FA. Compared to the control (J1), the 5% FA cemented specimen (J2) exhibited a 13.1% increase in uniaxial compressive strength (from 14.51 MPa to 16.41 MPa) and a 9.2% increase in elastic modulus, along with reduced elastic and plastic deformations (decreased by 22.2% and 28.6%, respectively), signifying improved deformation recovery. Failure mode analysis revealed that J2 developed a single dominant shear crack, while J1 exhibited severe splitting-shear failure with multiple cracks. SEM images of fracture surfaces further indicated that J2 possessed superior interfacial bonding. The reinforcement mechanism is attributed to the synergistic “physical filling-chemical bonding-crack passivation” effect of FA under the multicomponent admixture system. This study offers a green, high-performance grouting material for deep soft-rock mining applications.

     

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