Polymer functional coatings modified by ZrP-based composites: Preparation and applications on marine concrete

The development of high-performance coatings for concrete structures is essential to ensure their durability and service life. However, most of the proposed developed strategies suffer from various limitations, especially regarding the wear and biological-corrosion resistances of the coatings. This work reports a facile and efficient method to prepare effective composite coatings by nano-modification, in which the intercalated composites play structural and functional roles in the corrosion, wear, and biological-corrosion resistances. An in situ assembly synthesis was used to prepare the intercalated composites. The composites exhibited an innovative alternating skateboard structure and a functional composition. The silane-emulsion modified with the composites was prepared and coated on the mortar surface to systematically study its performance at the concrete interface. The results indicate the good dispersion stability of the innovative α-ZrP composites in the silane emulsion and their significant enhancement of the silane coatings' ability to improve the durability of marine concrete. The mechanisms of performance improved by the prepared composites through their unique lamellar structure and interlamellar silver-nanoparticle composition were also examined. The prepared composite coating exhibits a new strategic approach to solve problems associated with concrete applications and provides technical guidance for surface protection of marine concrete structures.