Sealing and anti-seepage polyurea coating design method based on nonlinear FEM simulation

Purpose Structural design theory and method for the polyurea coating system have rarely been developed. The normally used experience-based design method may lead to unsafe, unreasonable and uneconomic results. The purpose of this paper is to investigate the deformation and failure behaviour of the polyurea coating so as to propose a rational design method. Design/methodology/approach In this study, the fundamental theories concerning the nonlinear analysis of polyurea coating were discussed. Nonlinear Finite Element Method (FEM) models were built to investigate the mechanical behaviour, peeling behaviour and failure mode of the polyurea coating under various conditions, such as surface fracturing, surface hydraulic pressure and reverse hydraulic peeling. Findings The main conclusions are as follows. The peeled coating at the crack location exhibits a tensile-bending stress state. Coating material damage may occur at the stress concentration point. The maximum stress increases with the increase in the hydraulic pressure and cohesive strength. The peeling length of the coating decreases with the increase in cohesive strength and increases with the increase in fracture width. The reverse hydraulic pressure-induced blister edge stress concentration is the main trigger of the polyurea coating blistering damage. The blistering height decreases with increasing coating thickness and increases with increasing blistering radius and hydraulic load. The maximum stress increases with increasing blistering radius and hydraulic load. Finally, the frame of design and simple design programme were proposed. Originality/value Currently, a design method for polyurea anti-seepage coating can hardly be found. The reason is that the anti-seepage coating has only been recognized as a water-proofing layer, the mechanical behaviour of which has been ignored. This study focused on the mechanical behaviour of the anti-seepage coating and investigated the deformation and failure behaviour of the coating structure under various loading conditions through nonlinear FEM analysis. These research results offer a better understanding concerning the mechanical behaviour and design method of the polyurea anti-seepage coating.