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<p>Hydraulic concrete structures in high-altitude and cold climate environments are exposed to severe ultraviolet radiation, freeze–thaw cycling, and sustained hydraulic loading, conditions that often cause conventional waterproofing coatings to exhibit inadequate adhesion, poor curing, or premature degradation. This study evaluates a multilayer polyfluorosilicone composite coating system consisting of a nanoreactive primer, a polymeric anti-seepage layer, and a fluorosilicone topcoat through combined laboratory testing and field implementation on three hydropower structures, including conventional concrete, roller-compacted concrete (RCC), and concrete-faced rockfill dam (CFRD) surfaces. Laboratory results showed deep primer penetration ~ 7&#xa0;mm, high consolidation strength 1.25&#xa0;MPa, strong adhesion to both wet and dry concrete 5.14–6.06&#xa0;MPa, and stable low temperature curing at − 5 to 4&#xa0;°C. The weathering layer retained 80–110% of its tensile and elongation properties after UV, alkali, and thermal exposure, consistent with the high chemical stability of Si–O and C–F bonds. Field evaluations demonstrated uniform film formation, consistent adhesion governed by concrete cohesive failure, and absence of blistering or delamination across diverse structural substrates. The coating enhanced compatibility with polyurethane insulation, doubling interfacial strength compared with PU concrete bonding. The coating effectively enhanced compatibility with polyurethane insulation, doubling interfacial strength relative to PU concrete bonds. Thermal monitoring revealed elevated surface temperatures &gt; 70&#xa0;°C under solar radiation without inducing mechanical failure, indicating robust thermomechanical tolerance. Overall, the polyfluorosilicone composite system exhibited strong environmental resistance, moisture-tolerant bonding, and structural adaptability, supporting its suitability as a next-generation protective material for hydraulic structures operating under extreme climatic and mechanical conditions.</p>

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A multilayer polyfluorosilicone coating system for extreme hydraulic environments: design, performance, and field validation

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Nazim Hussain,
  • Zhang Guoxin,
  • Songhui Li,
  • Liu Xunan,
  • Xiangyu Luo,
  • Rahat Hussain,
  • Zhao Weiming,
  • Zeng Erlong

摘要

Hydraulic concrete structures in high-altitude and cold climate environments are exposed to severe ultraviolet radiation, freeze–thaw cycling, and sustained hydraulic loading, conditions that often cause conventional waterproofing coatings to exhibit inadequate adhesion, poor curing, or premature degradation. This study evaluates a multilayer polyfluorosilicone composite coating system consisting of a nanoreactive primer, a polymeric anti-seepage layer, and a fluorosilicone topcoat through combined laboratory testing and field implementation on three hydropower structures, including conventional concrete, roller-compacted concrete (RCC), and concrete-faced rockfill dam (CFRD) surfaces. Laboratory results showed deep primer penetration ~ 7 mm, high consolidation strength 1.25 MPa, strong adhesion to both wet and dry concrete 5.14–6.06 MPa, and stable low temperature curing at − 5 to 4 °C. The weathering layer retained 80–110% of its tensile and elongation properties after UV, alkali, and thermal exposure, consistent with the high chemical stability of Si–O and C–F bonds. Field evaluations demonstrated uniform film formation, consistent adhesion governed by concrete cohesive failure, and absence of blistering or delamination across diverse structural substrates. The coating enhanced compatibility with polyurethane insulation, doubling interfacial strength compared with PU concrete bonding. The coating effectively enhanced compatibility with polyurethane insulation, doubling interfacial strength relative to PU concrete bonds. Thermal monitoring revealed elevated surface temperatures > 70 °C under solar radiation without inducing mechanical failure, indicating robust thermomechanical tolerance. Overall, the polyfluorosilicone composite system exhibited strong environmental resistance, moisture-tolerant bonding, and structural adaptability, supporting its suitability as a next-generation protective material for hydraulic structures operating under extreme climatic and mechanical conditions.