Corrosion-Resistant Compounds Based on Polymer Matrices and Inorganic Additives

Corrosion of metal and reinforced concrete structures remains one of the most serious problems affecting strength and durability of products. It is primarily caused by environmental factors such as chloride, sulfate, and carbon dioxide exposure. Various methods are widely used to apply corrosion-resistant coatings onto metal surface.

Purpose: The aim of this work is to synthesize corrosion-resistant compounds based on polymer matrices and inorganic additives and investigate their corrosion-resistant properties.

Methodology/approach: It is shown that proposed compositions can be used as a complex protective coating. The introduction of a mixture of iron oxides with variable valence into the polyurethane polymer matrix significantly reduces the corrosion rate in chloride-containing environments due to secondary redox processes in the protective layer. The contact angle, adhesive strength are calculated, and the Pourbaix diagram is analyzed.

Research findings: Synthesized are corrosion-resistant compounds based on metal-phosphate binders incorporated into polyurethane, polyvinyl acetate or alkyd polymer matrix.

Practical implications: Polymer matrices combined with chemical additives and fillers have advantages in the protection efficiency, cost-effectiveness, and environmental sustainability, and such compounds can be used for corrosion protection.

1. Xiao, W., Peng, H., Yu, P., Cai, X., Luan, Z., Deng, S., Wang, S. An Integrated Epoxy Rust Conversion Coating: Its Anticorrosion Properties and Rust Conversion Mechanism. Journal of Alloys and Compounds. 2021; 853(5): 157005. DOI: 10.1016/j.jallcom.2020.157005

2. Xiong, Y.M., Zhan, Q.W., Zhang, X.C.H., Pan, Z.H.H. Study on Improving the Corrosion Resistance of Potassium Magnesium Phosphate Cement Coatings in Marine Environments through the Synergistic Effects of Crack Sealing and Ion Exchange. Journal of Building Engineering. 2025; 116: 114483. DOI: 10.1016/j.jobe.2025.114483

3. Wang, X., Liu, J., Jin, M., Yan, Y., Tang, J., Jin, Z. A Review of Organic Corrosion Inhibitors for Resistance under Chloride Attacks in Reinforced Concrete: Background, Mechanisms and Evaluation Methods. Construction and Building Materials. 2024; 433: 136583. DOI: 10.1016/j.conbuildmat.2024.136583

4. Shehnazdeep, Pradhan, B. A Study on Effectiveness of Inorganic and Organic Corrosion Inhibitors on Rebar Corrosion in Concrete: A Review. Pt. 2. Materials Today: Proceedings. 2022; 65: 1360–1366. DOI: 10.1016/j.matpr.2022.04.29

5. Alexander, M., Beushausen, H. Durability, Service Life Prediction, and Modeling for Reinforced Concrete Structures – Review and Critique. Cement and Concrete Research. 2019; 122: 17–29. DOI: 10.1016/j.cemconres.2019.04.018

6. Van Damme, H. Concrete Material Science: Past, Present, and Future Innovations. Cement and Concrete Research. 2018; 112: 5–24. DOI: 10.1016/j.cemconres.2018.05.002

7. Car corrosion in numbers. Available: www.mercasol.ru/statyi/korroziya-v-cifrax-statistika-kotoruyu-stoit-znat.html (accessed March 21, 2026 ). (In Russian).

8. Yuan, M., Zhao, L.L., Ping, T.T., Fu, C.Y., Xing, X.T., Chu, X.M., Liu, S.J., Tang, E.J. Fabrication of Cyclodextrin Modified Graphene Oxide Nanocontainers Loading Zinc Ion and its Application in water-Based Epoxy Resin Coatings. Colloids and Surfaces A: Physicochemical and Engineering Aspects. 2025; 726: 137679. DOI: 10.1016/j.colsurfa.2025.137679

9. del Castillo, A., Paulis, M., González, E. Direct-to-Metal Binders for Waterborne Anticorrosive Steel Coatings: Epoxy/styrene-acrylic Blends and Hybrids. Reactive and Functional Polymers. 2025; 215: 106378. DOI: 10.1016/j.reactfunctpolym.2025.106378

10. Zhou, C., Chen, Q., Zhao, J., Wang, S., Li, J., Ai, L., Li, T., Bo, C. Superhydrophobic Epoxy Resin Coating with Composite Nanostructures for Metal Protection. Materials Today Communications. 2024; 38: 107803. DOI: 10.1016/j.mtcomm.2023.107803

11. Ayaz, M., Sebit, G., Suleiman, A., Altaf, M., Zafar, A., Cheng, X., Feng, Y. Polymer and EcoFriendly Inhibitors for Corrosion Protection of Reinforced Concrete: A Comprehensive Review. Journal of Building Engineering. 2026; 119: 115119. DOI: 10.1016/j.jobe.2025.115119

12. Sudakas, L.G. Phosphate Binding Systems. St. Petersburg: Kvintet, 2008. 260 p. (In Russian)

13. Gerasimov, A.A. Phosphating and Oxidation of Steels, Zinc Coatings and Alloys. Corrosion: Materials, Protection. 2008; (11): 42–44. (In Russian)

14. Shchegrov, L.N. Phosphates of Divalent Metals. Kiev: Naukova Dumka, 1987. 216 p. (In Russian)

15. Apanasevich, N.S., Lapko, K.N., Kudlash, A.N., Sokol, A.A., Klyavlin, Y.D., Vishnevsky, K.V. Syntyhesis and Investigation of Heat-resistant Composites Based on Solid Magnesium-phosphate and Calcium-phosphate Binders. Zhurnal Belorusskogo gosudarstvennogo universiteta. Khimiya. 2021; 2: 50–61. DOI: 10.33581/2520-257X-2021-2-50-61 (In Russian)

16. Golynko-Vol'fson, S.L., Sychev, M.M., Sudakas, L.G., Skoblo, L.I. Materials Based on Metal Phosphates. Moscow: Khimiya, 1976. 200 p. (In Russian)

17. Kopeikin, V.A., Petrova, A.P., Rashkovan, I.L., Pak, Ch.G., Batrashov, V.M. Structure and Property Control of Phosphate Composite Materials. In: Proc. All-Russ. Sci. Conf. ‘Development Prospects of Materials Science in Construction: Energy and Resource Saving in Construction’. Chelyabinsk, 2011. Рр. 54–56. (In Russian)