Novel epoxy resin grouting material with high permeability and mechanical strength: Synthesis and curing mechanism

Conventional epoxy resin grouting materials exhibit drawbacks such as high initial viscosity, poor permeability, inadequate mechanical performance and an associated environmental impact, which have served to limit effective application. In this study, a novel epoxy resin grouting material has been synthesized, which is characterized by low viscosity (4.5 mPa·s), enhanced wettability (contact angle close to 0°), superior mechanical properties (compressive and tensile strength of 115.6 MPa and 26.6 MPa respectively), and is environmentally sustainable. During the curing process, furfural was added to the diluent, where it reacts with phenalkamine to form a Schiff-base polymer. Meanwhile, acetone condenses with furfural to generate a furan resin. These reactions, combined with the polymerization of epoxy resin and amine-based curing agents, contribute to the formation of a densely cross-linked composite network, significantly enhancing mechanical strength. Fourier transform infrared spectroscopy has established that there is no residual acetone present in the solidified epoxy, effectively circumventing potential environmental hazards. Scanning electron microscopy and compressive simulation have been employed to determine the influence of internal pores on mechanical properties, where a reduction in pore content attributed to the slow curing of active diluents and reduced volatilization is responsible for the superior mechanical properties. Simulated grouting experiments have demonstrated enhanced wetting behavior and permeability in fractured rock masses, enabling a more effective and uniform filling of geological defects. The findings of this study offer valuable insights that can inform the design and development of sustainable, high-performance epoxy grouting materials for anti-seepage reinforcement of constructions. • Novel epoxy grout material with ultra-low viscosity and near-zero contact angle. • High compressive (115.6 MPa) and tensile (26.6 MPa) strength. • Acetone-free cured product with enhanced environmental sustainability. • Mechanism of how active diluent improves mechanical properties via curing.