Experimental Study on Mechanical Behavior and Crack Evolution of Borehole Coal Samples Before and After Grouting Under Brazilian Splitting Conditions

Grouting and sealing in gas drainage boreholes are two of the critical measures to ensure efficient coal seam gas extraction. However, traditional cement grouting often leads to debonding and cracking of the slurry–coal cemented body under external load, resulting in poor sealing performance. To suppress crack propagation and achieve borehole reinforcement and efficient sealing, this study compares the mechanical properties and crack evolution characteristics of slurry–coal cemented samples grouted with different modified materials. Five types of cement-based sealing materials, including ordinary Portland cement, were used for grouting coal rock in boreholes. By employing an acoustic emission signal acquisition system and a non-contact full-field strain measurement system, the tensile mechanical properties of coal before and after grouting were compared. The influence of material properties on the reinforcement capacity of borehole coal was analyzed, along with the failure process characteristics and final failure morphology of the slurry–coal cemented body under Brazilian splitting load. Finally, the effects of material toughness and bond strength on the brittleness index and failure mode of the slurry–coal cemented samples under Brazilian splitting conditions were discussed. The results show that the tensile strength improvement rates of the samples were 26.9%, 55.3%, 48.4%, 8.6%, and 45.6%, respectively. Distinct from previous studies focusing on fractured grouting or intact coal rock, this work for the first time systematically reveals the non-monotonic influence of the combination of material toughness and bond strength on the reinforcement effect of borehole coal samples and proposes an evaluation framework based on quantitative acoustic emission crack type analysis and the concept of effectiveness threshold. The varying degrees of tensile strength enhancement indicate differences in the reinforcement capabilities of grouting materials with different properties. The acoustic emission signals during the failure process of the slurry–coal cemented body exhibited typical stage-specific characteristics, though material properties altered the failure modes. By quantifying the intrinsic properties and crack characteristics of the slurry–coal cemented body using the brittleness index and grayscale histograms, this study provides a theoretical basis for guiding efficient sealing of gas drainage boreholes through an in-depth understanding of the mechanical behavior and crack evolution of borehole coal samples before and after grouting under Brazilian splitting conditions.