Performance Optimization and Anchorage Enhancement of Cement-Based Grouts Using Fly Ash and Metakaolin

Cement-based grouts used in anchorage engineering often suffer from insufficient flowability, bleeding, and inadequate early-age strength, which may impair grout filling quality and interfacial bonding. This study investigated the synergistic use of fly ash (FA) and metakaolin (MK) to optimize the fresh properties, strength development, microstructure, and early-age anchorage performance of cement-based grouts. Rheological behavior, bleeding rate, and compressive strength were evaluated for grouts with different FA and MK contents, and the overall performance was ranked using the entropy-weighted TOPSIS method. X-ray diffraction and scanning electron microscopy were further employed to clarify the underlying microstructural evolution, and laboratory pull-out tests were conducted to verify the early-age anchorage effectiveness of the selected optimal mixtures. The results showed that the optimal performance was achieved at 15–20% FA and 3–6% MK. Within this range, grout viscosity decreased from 0.24 to 0.16 Pa·s, bleeding rate decreased from 13% to 2%, and compressive strength increased markedly at both 7 and 28 days. The optimized grout also increased the peak interfacial shear stress from 0.440 to 0.978 MPa. These improvements were associated with accelerated hydration, reduced CH and residual clinker phases, and a denser hydration-product network. The pull-out specimens failed predominantly along the grout–rock/soil interface, and the improved anchorage response was attributed to a denser hydration-product network that reduced pores and interfacial defects and promoted more efficient shear-stress transfer.