煤矿巷道支护中，水泥基薄喷材料相比于传统喷射混凝土具有喷层薄、施工快、用量小、运输成本低、与围岩表面贴合更好等优点，近年来受到广泛关注。当巷道围岩变形时，水泥基薄喷材料易发生脆性断裂，且成本高昂。工业固废粉煤灰具有潜在的火山灰活性。将粉煤灰活性激发，以活化粉煤灰部分替代水泥，制备粉煤灰基薄喷材料，并以聚合物及柔性纤维对其脆性缺陷进行改性，用于煤矿巷道支护，将大幅降低支护成本，减少粉煤灰环境污染，实现循环经济。

在分析粉煤灰理化性能的基础上，通过正交试验确定了活化粉煤灰的复掺活化剂配比为占粉煤灰质量3.97%的氧化钙、5.45%的无水硫酸钠、1.00%的九水硅酸钠，揭示了粉煤灰活化机理。在此基础上，研究了活化粉煤灰掺量、质量浓度及胶沙比对薄喷材料流动性及强度的影响规律，结合薄喷试样的扫描电镜分析，通过正交试验及响应面法，确定了薄喷材料的基础配比为质量浓度76.9%，胶沙比1.18:1，活化粉煤灰掺量为73.7%。

以聚丙烯纤维及羟乙基纤维素分别对粉煤灰薄喷材料韧性及黏结性能进行改性，研究了聚丙烯纤维长度、体积掺量以及羟乙基纤维素掺量对薄喷材料流动性、强度、韧性及黏结性能的影响规律，通过扫描电镜分析了薄喷材料的微观结构，揭示了聚丙烯纤维增韧机理及羟乙基纤维素对薄喷材料黏结性能的改性机理。研究结果表明，聚丙烯纤维对裂纹扩展阻碍作用显著，其合理长度为9 mm，合理体积掺量为1.5%。掺入后聚丙烯纤维使粉煤灰薄喷材料7 d、28 d抗折强度、抗压强度及劈裂抗拉强度均有提升，其中劈裂抗拉强度相较于未掺入聚丙烯纤维试样分别提升145%、79%。羟乙基纤维素对聚丙烯纤维与基体界面以及薄喷材料与岩样界面黏结性能提升明显。掺入0.05%的羟乙基纤维素后，粉煤灰基薄喷材料7 d、28 d黏结强度相较于未掺入羟乙基纤维素的试样分别提升333%、201%。

利用聚羧酸高效减水剂及JS-SN III无碱型液体速凝剂（单一硫酸铝组份）分别对粉煤灰薄喷材料流动性、泌水率、凝结时间等性能进行调控，分析了聚羧酸减水剂及JS-SN III无碱型液体速凝剂掺量对浆料流动性、泌水率、凝结时间及试样强度的影响规律，通过微观形貌分析，揭示了聚羧酸减水剂及JS-SN III无碱型液体速凝剂调控机理。研究结果表明，聚羧酸减水剂能够提升浆料流动性，使试样致密，提升试样28 d强度，但过掺时会导致浆料保水性能下降，泌水率增大。添加0.1%聚羧酸减水剂，薄喷材料浆料稠度提升至107.3 mm，泌水率降低到2.1%。掺量10%的JS-SN III无碱液体速凝剂能够使浆料初凝时间由2.5 h降低到4 min，终凝时间由3 h缩短至13 min，试样1 d无侧限抗压强度提升了600%，达到0.6 MPa，但会导致中后期强度小于10%的削减。改性及调控后的粉煤灰薄喷材料龄期为28 d的试样抗压强度为22.21 MPa，劈裂抗拉强度为4.26 MPa，粘结强度为3.39 MPa。

以活化粉煤灰部分替代水泥制备了巷道支护用薄喷材料，所用活化粉煤灰质量占胶凝物质总质量73.7%，降低了煤矿巷道支护成本，为工业固体废弃物大宗化利用提供了可行途径，对生态保护、资源循环及可持续发展具有重要意义。

In the support of coal mine tunnels, cement-based thin spray-on liner materials have attracted widespread attention in recent years due to their advantages over traditional shotcrete, such as thin spray layer, fast construction, small dosage, low transportation cost, and better adhesion to the surrounding rock surface. When the surrounding rocks of the tunnel are deformed, the cement-based thin spray-on liner materials is prone to brittle fracture, and the cost is high. Fly ash, a sort of industrial solid waste, has potential pozzolonicity. Activating the potential pozzolonicity of fly ash, partially replacing cement with activated fly ash, to prepare fly ash based thin spray-on liner materials, and modifying their brittle defects with polymers and flexible fibers for supporting in the coal mine tunnel will significantly reduce support costs, reduce environmental pollution caused by fly ash, and achieve circular economy.

On the basis of the physical and chemical properties of fly ash, the composite activator ratio of activated fly ash was determined to be 3.97% CaO, 5.45% Na₂SO₄, and 1.00% Na₂SiO₃, through orthogonal experiments accounting for the mass of fly ash. The activation mechanism of fly ash is revealed in this research. On this basis, the influence of activated fly ash content, mass concentration, and cement sand ratio on the flowability and strength of thin spray-on liner materials was studied. Combined with scanning electron microscopy analysis of thin spray-on liner samples, orthogonal experiments and response surface methodology were used to determine the basic ratio of thin spray-on liner materials as 76.9% mass concentration, 1.18:1 cement sand ratio, and 73.7% activated fly ash content.

The toughness and adhesive properties of thin spray-on liner materials with fly ash were modified with polypropylene fibers and hydroxyethyl cellulose, respectively. The effects of polypropylene fiber length and volume content, and hydroxyethyl cellulose content on the flowability, strength, toughness, and adhesive properties of the thin spray-on liner materials were studied. The microstructure of the thin spray-on liner materials was analyzed using scanning electron microscopy, the reinfocing mechanism of polypropylene fibers and the modification mechanism of hydroxyethyl cellulose on the adhesive performance of thin spray-on liner materials is revealed in this study. The results indicate that polypropylene fibers have a significant inhibitory effect on crack propagation, with a reasonable length of 9 mm and a reasonable volume content of 1.5%. The addition of polypropylene fibers improved the flexural strength, compressive strength, and splitting tensile strength at 7 d and 28 d of the thin spray-on liner materials with fly ash, with splitting tensile strength increased by 145% and 79% at 7 d and 28 d respectively compared to the sample without polypropylene fibers. Hydroxyethyl cellulose significantly improves the adhesive performance between polypropylene fiber and matrix interface, as well as between thin spray-on liner materials and rock sample interface. After adding 0.05% hydroxyethyl cellulose, the adhesive strength of the thin spray-on liner materials with fly ash increased by 333% and 201% respectively after 7 d and 28 d compared to the sample without hydroxyethyl cellulose.

The flowability, bleeding rate, and setting time of thin spray-on liner materials with fly ash were regulated using polycarboxylic acid high-efficiency water reducing agent and JS-SN III alkali free liquid accelerator (single aluminum sulfate component). The influence of the dosage of polycarboxylic acid water reducing agent and JS-SN III alkali free liquid accelerator on the flowability, bleeding rate, setting time, and sample strength of the slurry was analyzed through microscopic morphology analysis, the regulatory mechanism of polycarboxylic acid water reducer and JS-SN III alkali free liquid accelerator is revealed. The results indicate that polycarboxylic acid water reducing agent can improve the fluidity of the slurry, make the samples dense, and enhance the 28 d strength of the samples. However, excessive addition can lead to a decrease in the water retention performance of the slurry and an increase in the bleeding rate. By adding 0.1% polycarboxylic acid water reducing agent, the consistency of the thin spray material slurry was increased to 107.3 mm, and the bleeding rate was reduced to 2.1%. The addition of 10% JS-SN III alkali free liquid accelerator can reduce the initial setting time of the slurry from 2.5 h to 4 min, and shorten the final setting time from 3 h to 13 min. The unconfined compressive strength of the samples after 1 d has increased by 600%, reaching 0.6 MPa, but it will lead to a reduction of strength less than 10% in the middle and later ages. The thin spray-on liner materials with fly ash has a compressive strength of 22.21 MPa at 28 d, a splitting tensile strength of 4.26 MPa, and a bonding strength of 3.39 MPa after modification and regulation.

Activated fly ash was partially used to replace cement in the preparation of thin spray-on liner materials for tunnel support. The mass of activated fly ash used accounted for 73.7% of the total mass of cementitious materials, reducing the cost of coal mine tunnel support and providing a feasible approach for the large-scale utilization of industrial solid waste. It is of great significance for ecological protection, resource circulation, and sustainable development.

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