Mechanism and Optimization of Metakaolin-Based Geopolymer Grout Under High Water-to-Solid Ratio: Steel Slag as a Calcareous Source

This study systematically examines the fluidity, setting time, mechanical properties, and microstructural evolution of metakaolin-based geopolymer grouting materials with a relatively high water-to-solid (W/S) ratio window. A four-factor, three-level orthogonal experimental design was employed to identify the dominant factors and main effect trends of W/S ratio, alkali dosage, water glass modulus (Ms, molar ratio of SiO2 to Na2O in alkali solution), and steel slag content on the material’s performance. The results indicated that the W/S ratio predominantly governed fluidity, while the alkali content was the primary controlling factor for setting time and early-age strength. An intermediate range of water glass modulus with a value of 1.6 provided balanced performance. The incorporation of steel slag with a range of 10–20% showed an age-dependent contribution: it not only tended to improve the rheology of the paste but also the later-age strength. XRD, FTIR, and SEM/EDS results suggested that the hardened binders were dominated by amorphous products, where alumimosilicate gel (N-A-S-H) and Ca-containing gel (C-S-H/C-A-S-H) may coexist depending on calcium availability and activator chemistry. The proposed parameter ranges are valid within the studied design space and provide guidance for the mix design of high-W/S geopolymer grout.