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This article discusses the effects of glass powder (GP) replacements and sodium hydroxide (NaOH) molarity on the rheological, fresh, mechanical and microstructure characteristics of slag-based mechanochemical geopolymer (MG) grout. A conventionally activated geopolymer grout and an ordinary Portland cement (OPC) grout were also investigated for comparison. Four glass powder replacement ratios were used (0%, 10%, 20% and 30% by the total precursor weight) to prepare slag-based mechanochemical geopolymer at three NaOH concentrations (1.25, 2.5 and 3.75 molars). The experimental results showed that the rheological behaviour of MG grouts was considerably reduced, whereas the setting time and the bleeding capacity value increased when slag was substituted with 0%–30% GP. However, after 28 days, the unconfined compressive strength (UCS) improved by 2%–13% when 10%–20% GP was used as a slag replacement, then dropped by 4% when 30% GP was substituted. The results confirmed that both geopolymer grouts irrespective of the activation method had shorter setting time and more stable bleeding capacity than OPC grout. The results also revealed that the UCS of geopolymer grout is enhanced by 18% when the source materials are activated by the mechanochemical method compared to the conventional activation of geopolymer grout. The microstructure results revealed that the activation method had a considerable effect on the microstructure of geopolymer grout because the ball milling process increased the surface area and reduced the particle size of slag compared to conventionally activated geopolymer grout. © 2022 Informa UK Limited, trading as Taylor & Francis Group.