Optimal formulation design of silicate-modified polymer based grouting material for reinforcing silty fine sand stratum

To address the material requirements for grouting reinforcement in fine sand strata, a novel silicate-modified polymer two-component grouting material was designed. In this material, the traditional organic polyol component of the two-component polymer was replaced with an inorganic silicate (water glass) component, along with the addition of tertiary amine catalysts, organotin catalysts, water. The response surface methodology (RSM) was used to statistically predict the performance of the modified polymer grouting material. The effects of four parameters (two-component mass ratio, tertiary amine catalyst content, organotin catalyst content, and water content) and their interactions on response variables (gelation time, polymer solids strength, cemented body strength) were investigated. Based on a comprehensive consideration of various performance requirements for grouting materials in loose fine sand strata, multi-objective optimization was employed to determine the optimal formulation of the modified polymer grouting material (A/B ratio of 0.85, tertiary amine catalyst at 2.48%, organotin catalyst at 0.63%, and water at 1.87%). A series of experimental tests were conducted to evaluate the material properties of the optimal formulation, and its mechanical performance and microstructural characteristics were compared with those of traditional polymer grouting materials to verify the proposed formation mechanism of the modified polymer. The results demonstrated that the proposed design method effectively determines the optimal grouting material formulation. The optimized modified polymer grouting material exhibited excellent comprehensive performance. Finally, the optimized modified polymer grouting material was applied in a pavement repair project on a section of a highway. After grouting, the structural layer's uniform integrity was significantly restored, the damaged areas were effectively repaired, the modified polymer slurry showed good diffusion, and the repair effect was satisfactory, meeting the engineering requirements for grouting in loose fine sand strata. • A novel, cost-effective grouting material based on inorganic salt-modified polymers is proposed, meeting the specific requirements for grouting in fine sand strata. • The optimal formulation was determined through RSM, enhancing gelation time and compressive strength with minimal experimental costs. • The modified material exhibits better mechanical properties and a more uniform microstructure compared to traditional polymer grouts.