<p>The corrosion of equipment in marine environments is becoming increasingly severe. To address this issue, there is an urgent need to develop novel coating materials that exhibit superior anti-corrosion performance and environmentally friendly characteristics. This can be achieved by enhancing the properties of waterborne epoxy resin cold-sprayed zinc coatings through various modification techniques. In this study, a cold-sprayed zinc coating, co-prepared from waterborne epoxy resin and zinc powder, was modified using the silane coupling agent KH560. The morphology of the coating was examined, and its corrosion resistance was evaluated primarily through electrochemical and immersion tests. Additionally, the influence of KH560 content (ranging from 1 to 7%) on the coating’s performance was investigated. The results indicate that at a KH560 content of 5%, the coating forms a Zn₄(SiO₄)₂·5H₂O compound, which enhances adhesion, density, and barrier properties, thereby significantly improving corrosion resistance. During the electrochemical process, the coating exhibited the highest corrosion potential (− 0.703&#xa0;V) and the lowest corrosion current (4.965 × 10⁻⁷A/cm²). Electrochemical circuit fitting analysis revealed that the coating had the highest resistance and the lowest capacitance, indicating maximum charge transfer resistance and minimum double-layer capacitance, which strongly confirms its excellent anti-corrosion performance. In conclusion, this study successfully developed a high-performance KH560-modified waterborne epoxy resin cold-sprayed zinc coating, providing robust support for the long-term anti-corrosion of marine equipment.</p> Graphical abstract <p></p>