Sustainable Rheology of Clay–Cement–Fly Ash Sealing Suspensions Applicable in Hydrotechnical Construction

The development of eco-efficient construction materials requires optimisation strategies that reduce cement consumption, valorise industrial by-products, and enhance performance without increasing material demand. Clay–cement sealing suspensions used in geotechnical engineering offer significant sustainability potential due to their high mineral content and compatibility with supplementary cementitious materials such as siliceous fly ash. The early-age rheological properties are essential for the design of geotechnical sealing barriers, yet the influence of chemical additive sequencing on flow behaviour remains poorly understood. This study examines how the priority of sodium silicate addition—introduced either before cement and siliceous fly ash (the “Prior” series) or after them (the “After” series)—affects the flow curves, yield stress, thixotropy, and equilibrium shear stress of clay–cement–fly ash sealing suspensions. Ascending flow curves were fitted to the Casson, Herschel–Bulkley, and Ostwald–de Waele models, and a shear-rate-resolved thixotropic power density analysis was applied to decompose the hysteresis behaviour. The results demonstrate that the Prior series produces deflocculated colloidal clay networks with localised cementitious agglomerates, exhibiting lower shear stresses at low shear rates but markedly higher yield stress amplitudes and larger hysteresis loop areas. The After series yields more uniformly distributed nucleation–coagulation networks with smaller hysteresis loops and pronounced structural rebuilding at low shear rates during the ramp-down phase. These findings provide a physicochemical framework for tailoring the early-age rheology of clay–cement suspensions through controlled additive sequencing, with direct implications for pumpability, injectability, and post-placement structural recovery in geotechnical applications.