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.

To increase the hydration reaction rate and the amount of hydration products, different types and proportions of acids were mixed into mortars. The effects of the acid type and content on the early compressive strength of cement-based materials and the strengthening mechanism were assessed via X-ray diffraction and Fourier-transform infrared spectrum analyses. The addition of acetic acid or hydrochloric acid significantly increased the compressive strength of mortars at 1 d and 3 d, and slightly increased it at 28 d. With increasing acetic acid content, the strengthening effect increased first and then decreased with the best content at 4%. With increasing hydrochloric acid content, the strengthening effect decreased gradually with the best content at 2%.

A self-foaming alkali-activated lightweight material was prepared by the pretreatment of municipal solid waste incineration bottom ash (BA). The low weight could be achieved without adding a foaming agent by using the low-density and self-foaming expansion characteristics of BA in combination with a strong alkali. The effects of BA, liquid sodium silicate (LSS), and calcium hydroxide (CH) on dry and wet densities, as well as water absorption, are discussed. The results show that increasing the BA content can significantly improve the foaming effect and reduce the dry and wet densities of specimens. However, it also leads to a sudden decrease in compressive strength and a significant increase in water absorption. LSS and CH can significantly improve the ability to seal bubbles by accelerating condensation, and they further reduce dry and wet densities without significantly improving water absorption. It is most effective at BA, LSS, and CH contents of 60, 20, and 2%, respectively.

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.

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.