Sustainable coating solutions with halloysite/aerosil/zinc borate/coconut oil for construction pipes: system optimization, performance validation and green chemistry evaluation

This research focused on developing sustainable solutions by creating water-based coatings reinforced with a hybrid blend of additives, including coconut oil, aerosil, halloysite, and zinc borate. These components were integrated into the coating matrix at concentration levels ranging from 0% to 6% (w/w). To determine the most effective formulation, the Design Expert optimization program was utilised to generate necessary tables and graphs. The resulting ‘optimum’ coating was then rigorously compared against a standard reference coating to evaluate its performance. Statistical analysis confirmed the reliability of the study, as the R² value of 0.9167 indicated that the model successfully accounted for 91.67% of the experimental variation. Additionally, the Adeq Precision coefficient reached 12.8934, proving that the model had a strong signal-to-noise ratio and high predictive validity. Various characterization techniques, such as Thermogravimetric and Differential Thermal Analysis (TG/DTA), Scanning Electron Microscopy (SEM), contact angle test, and color measurement, were performed to assess the coating’s properties. The study concluded that these hybrid additives enhanced protection and physical durability. Ultimately, this research offered an innovative, low-cost, and eco-friendly approach to extending the service life of industrial iron infrastructure.