Water-based polymer resins as sustainable coatings for corrosion protection

• A.Kh. Narzullaev^1,2, Kh.Ch. Mirzakulov³, G.E. Melikulova⁴, M.G. Yulchieva⁵, A.K. Nomozov⁵, O. Adurakhmanov⁶, O.A. Mengboev⁷, Sh.I. Khaitova⁸ and L.E. Kholmurodova⁹

¹ Tashkent Scientific Research Institute of Chemical Technology, Shura-bazar, Zangiata District, Tashkent Region 111116, Uzbekistan
² University of Economics and Pedagogy, 13 Islam Karimov St., Karshi 180109, Uzbekistan
³ Network Center for “Retraining and Advanced Training of Pedagogical Personnel” at the Tashkent Institute of Chemical Technology, Tashkent, 100011, Uzbekistan
⁴ Department of Chemical Technology of Inorganic Substances named after Academician M. Nabiev, Tashkent Institute of Chemical Technology, Tashkent, 100011, Uzbekistan
⁵ Department of Chemical Technology, Termez State University of Engineering and Agrotechnologies. Termez 190100, Uzbekistan
⁶ Department of Light Industry and Food Technologies, Termez State University of Engineering and Agrotechnologies, Termez 190100, Uzbekistan
⁷ Faculty of Pedagogy and Social-Humanitarian Sciences, Foreign languages, Termez University of Economics and Eervice. Termez, 190111, Uzbekistan
⁸ Department of microbiology, public health, hygiene, and management, Termez Branch of Tashkent State Medical University, Temez, Uzbekistan
⁹ Department of Inorganic Chemistry, Karshi State University, Karshi 180119, Uzbekistan

Abstract: Water-based polymer resins have emerged as environmentally sustainable alternatives to conventional solvent-borne coatings for corrosion protection of metallic substrates. This comprehensive review examines the classification, corrosion protection mechanisms, performance evaluation, and sustainability aspects of waterborne polymer coatings. The major resin systems include waterborne epoxy, polyurethane, acrylic, alkyd, and hybrid formulations, which provide corrosion protection through barrier formation, inhibitive action, and passivation mechanisms. Advanced formulations incorporating nanofillers such as graphene oxide, hexagonal boron nitride, and silica nanoparticles demonstrate significant performance enhancements, with impedance increases of up to 200-fold and corrosion current reductions by three orders of magnitude compared to unmodified systems. Bio-based feedstocks and conducting polymers further enhance both sustainability and protective performance. Electrochemical impedance spectroscopy, potentiodynamic polarization, and salt spray testing remain the primary evaluation methods, with quantitative metrics demonstrating that optimized waterborne systems can match or exceed the performance of traditional solvent-borne coatings. Environmental benefits include volatile organic compound (VOC) reduction by over 90%, elimination of chromate-based inhibitors, and incorporation of renewable bio-based materials. Key challenges include long-term durability validation under harsh environmental conditions, scalability of nanocomposite formulations, and comprehensive life-cycle assessment. Future directions emphasize the development of self-healing coatings, smart release systems, and fully bio-based formulations with enhanced multifunctional properties. This review synthesizes current knowledge and identifies critical research priorities to advance waterborne polymer coatings toward widespread industrial adoption for sustainable corrosion protection.

Keywords: waterborne coatings, polymer resins, corrosion protection, sustainable coatings, VOC reduction, green chemistry

Int. J. Corros. Scale Inhib., 2026, 15, no. 3, 164-200
doi: 10.17675/2305-6894-2026-15-3-7

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