Development and Multi-Scale Evaluation of a Novel Polyfluorosilicone Triple-Layer Anti-Seepage Coating for Hydraulic Concrete

The deterioration of concrete hydraulic structures caused by chemical factors, seepage, and environmental stress necessitates advanced protective coatings that enhance durability, flexibility, and environmental sustainability. Conventional protective systems often exhibit limited durability under combined hydraulic, thermal, and chemical stress. In this study, a novel polyfluorosilicone-based coating system is presented, which integrates a deep-penetrating nano-primer for substrate reinforcement, a crack-bridging polymer intermediate layer for impermeability, and a polyfluorosilicone topcoat providing UV and weather resistance. The multilayer architecture addresses the inherent trade-offs between adhesion, flexibility, and durability observed in conventional waterproofing systems. Informed by a mechanistic study of interfacial adhesion and failure modes, the coating exhibits outstanding high mechanical and performance characteristics, including a mean pull-off bond strength of 4.56 ± 0.14 MPa for the fully cured triple-layer coating system, with cohesive failure occurring within the concrete substrate, signifying a bond stronger than the material it protects. The system withstood 2.2 MPa water pressure and 200 freeze–thaw cycles with 87.2% modulus retention, demonstrating stable mechanical and environmental durability. The coating demonstrated excellent resilience, showing no evidence of degradation after 1000 h of UV aging, 200 freeze–thaw cycles, and exposure to alkaline solutions. This water-based formulation meets green-material standards, with low volatile organic compound (VOC) levels and minimal harmful chemicals. The results validate that a multi-scale, layered design strategy effectively decouples and addresses the distinct failure mechanisms in hydraulic environments, providing a robust and sustainable solution.