Development of protective coating system using natural rubber – acrylic polyol resin for mild steel

Purpose The purpose of this study is to develop a protective coating system on mild steel panel incorporating epoxidized natural rubber with acrylic polyol resin. Design/methodology/approach In this work, a novel attempt is made to develop binder coatings using epoxidized natural rubber-based material and an organic resin (acrylic resin) for corrosion protection on metal substrate. Seven different samples of multifunctional coatings are developed by varying the compositions of epoxidized natural rubber (ENR) and acrylic resin. The properties of the developed coatings have been characterized using analytical methods such as Fourier transform infrared spectroscopy (FTIR) and electrochemical impedance spectroscopy (EIS). EIS has been carried out for 30 days to evaluate the corrosion resistance after immersing into 3.5 wt.% of sodium chloride. Cross hatch cut tester (CHT) has been used to study the adhesive properties. UV–Visible Spectroscopy (UV–Vis) was also used to assess changes in the coating-film transparency of the natural rubber-based coating systems in this study. Findings The developed coatings have formed uniform layer on the substrate. CHT results show excellent adhesion of the coatings. Higher concentrations of ENR have higher transparency level, which reduces when the acrylic concentration increases. FTIR analysis confirms the crosslinking that occurred between the components of the coatings. Based on the impedance data from EIS, the incorporation of natural rubber can be an additive for the corrosion protection, which has the coating resistance values well above 108Ω even after 30 days of immersion. Practical implications The blending method provides a simple and practical solution to improve the strength and adhesion properties of acrylic polyol resin with epoxidized natural rubber. There is still improvement needed for long-term applications. Originality/value The work has been conducted in our laboratory. The combination of natural rubber-based materials and organic resins is a new approach in coating research.