Corrosion of metals and fire-related damage are major challenges faced by industries
worldwide, leading to enormous economic losses, safety concerns, and increased
maintenance costs. To address these challenges, researchers from IIT Bhilai, in collaboration
with IIT Patna, have developed a new multifunctional polymer coating that can protect metal
surfaces from corrosion while also improving fire safety.
A research team from the Department of Chemistry, IIT Bhilai, in collaboration with
researchers from IIT Patna, led by Dr. Sanjib Banerjee and comprising Nishikanta Singh,
Swarup Maity, Soumen Ghosh, and Dr. Subrata Chattopadhyay, has developed a new class of
multifunctional polymer coatings. Protective coatings are widely used to safeguard metallic
structures and devices from environmental degradation. However, most existing coatings are
designed to perform only a single function, often requiring multiple layers or additional
additives to achieve comprehensive protection. Addressing this challenge, the team
engineered a phosphorus- and fluorine-containing polymer coating capable of integrating
several critical functionalities within a single material.
The newly developed coating can intelligently adapt to its surroundings while providing
multiple layers of protection. It helps prevent rust and corrosion on metal surfaces, adheres
strongly without easily peeling off, and improves fire safety by slowing down the spread of
flames. Extensive testing showed that the coating remains effective even under harsh
conditions such as saltwater exposure and prolonged outdoor weathering. By combining
several important functions into a single material, this technology could help extend the
lifetime of infrastructure, vehicles, industrial equipment, and safety-related materials while
reducing maintenance costs and improving reliability.
“Industries often rely on multiple coatings or treatments to achieve corrosion protection,
durability, and fire resistance,” said Dr. Sanjib Banerjee, who led the research. “Our work
demonstrates that these important properties can be integrated into a single coating material,
offering a simpler, more efficient, and potentially cost-effective solution for a wide range of
applications.”
Key Benefits are Effectively prevents rust and degradation of metal surfaces, extending the
service life of infrastructure and industrial equipment; Slows flame propagation and improves
fire resistance, making materials safer for use in safety-critical environments; Forms durable
coatings that strongly adhere to metallic surfaces, reducing peeling and improving long-term
reliability; Maintains performance under harsh conditions such as saltwater exposure, outdoor
weathering, and fluctuating environmental conditions.
By integrating several important protective functions into a single material platform, this
technology supports India’s vision for durable infrastructure, industrial safety, and sustainable
manufacturing under initiatives such as Atmanirbhar Bharat, Make in India, PM Gati Shakti,
and the National Infrastructure Pipeline. The coating has the potential to enhance the
longevity and safety of transportation systems, industrial facilities, marine structures, energy
devices, and other critical infrastructure while reducing maintenance requirements and
associated economic losses.
This research has been published in the world-renowned journal Advanced Functional
Materials (Wiley-VCH), highlighting IIT’s growing contribution to advanced materials
research for industrial sustainability and infrastructure protection.
