Performance and Microstructural Characteristics of Cement-Based Grouting Materials Modified with Fly Ash and Corrosion-Control Admixtures

Grouting materials used in water-rich and chloride-exposed environments require adequate workability, mechanical performance, and durability. To optimize the formulation, a series of orthogonal tests was conducted to assess how fly ash (10–30%), rust inhibitor (1–3%), and anti-corrosion agent (2–6%) affect the fresh and hardened properties of cement grouts at a constant water-to-binder ratio of 0.5. Setting behaviour, mechanical properties, chloride ion penetration resistance, pore structure, and hydration products were investigated. Fly ash and the anti-corrosion admixture prolonged the setting time. The highest 28-day compressive and flexural strengths were obtained at 20% fly ash. At 30%, the dilution effect outweighed the later-age pozzolanic contribution and slowed strength development. Within the investigated range, 6% anti-corrosion admixture provided the greatest improvement in strength and chloride ion penetration resistance, whereas the rust inhibitor had a smaller effect on the charge passed. Mixtures containing 20% fly ash and 4–6% anti-corrosion admixture exhibited lower porosity and a refined pore-size distribution. By contrast, 30% fly ash resulted in a less favourable pore structure. SEM and XRD results indicated a denser matrix at 28 days, consistent with continued cement hydration and the later-age pozzolanic reaction of fly ash. Previous studies have mainly focused on individual mineral or chemical admixtures, whereas the combined effects of fly ash, rust inhibitors, and anti-corrosion admixtures under fixed workability conditions remain insufficiently understood. This study reveals their distinct and complementary roles, providing a basis for the multi-objective optimisation of grouting materials in chloride-rich and water-saturated environments. Overall, 20% fly ash, 4–6% anti-corrosion admixture, and 1–2% rust inhibitor provided the best performance balance under the investigated conditions.