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<p>To address the high costs and performance limitations of polyurethane (PU) grouting materials, this study developed a novel magnesium-slag-based geopolymer/PU composite via a facile “one-pot” synthesis. By utilizing sodium silicate (SS) as a dual-functional agent, the magnesium slag and fly ash mixture was transformed from a passive filler into an active reinforcement phase. The synergistic effects of the SS modulus and solid-waste loading on mechanical properties and microstructural evolution were systematically evaluated. The results show that when the modulus of the sodium silicate solution is 1.62 and the addition amount of solid waste is 70%, the compressive strength of the composite grouting material can be 84% higher than that of the pure polyurethane grouting material. While high mineral loading induces interfacial stress concentrations that reduce bond strength, the composite retains sufficient adhesion for geotechnical applications. Mechanistic analysis via FTIR and microscopy reveals that SS functions simultaneously as an alkaline activator for geopolymerization and a chemical modifier for the organic matrix. The synergy between chemical Si–O–Si/C–O–C linkages and the physical filling of geopolymer gels results in a dense organic-inorganic interpenetrating network (IPN). This work offers a scalable strategy for magnesium slag valorization and the sustainable upgrading of road repair materials.</p>

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Preparation and mechanical properties of magnesium-slag–based geopolymer/polyurethane composite grouting materials

  • 期刊论文

  • 发表日期：

    2026年5月13日

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  • Mingkai Xu,
  • Hongquan Ren,
  • Caiping Chu,
  • Yang Luo,
  • Tao Ai

摘要

To address the high costs and performance limitations of polyurethane (PU) grouting materials, this study developed a novel magnesium-slag-based geopolymer/PU composite via a facile “one-pot” synthesis. By utilizing sodium silicate (SS) as a dual-functional agent, the magnesium slag and fly ash mixture was transformed from a passive filler into an active reinforcement phase. The synergistic effects of the SS modulus and solid-waste loading on mechanical properties and microstructural evolution were systematically evaluated. The results show that when the modulus of the sodium silicate solution is 1.62 and the addition amount of solid waste is 70%, the compressive strength of the composite grouting material can be 84% higher than that of the pure polyurethane grouting material. While high mineral loading induces interfacial stress concentrations that reduce bond strength, the composite retains sufficient adhesion for geotechnical applications. Mechanistic analysis via FTIR and microscopy reveals that SS functions simultaneously as an alkaline activator for geopolymerization and a chemical modifier for the organic matrix. The synergy between chemical Si–O–Si/C–O–C linkages and the physical filling of geopolymer gels results in a dense organic-inorganic interpenetrating network (IPN). This work offers a scalable strategy for magnesium slag valorization and the sustainable upgrading of road repair materials.