Dual Optimization of Efficiency and Surface Smoothness in Water-Based Release Agents for Concrete
Publish Time: 2026-02-04
In the production of precast concrete components, the performance of water-based release agents directly affects construction efficiency and finished product quality. Water-based concrete release agents, with their environmentally friendly characteristics and comprehensive performance advantages, are gradually becoming the mainstream choice in the industry. Their core value lies in achieving a dual improvement in release efficiency and surface smoothness through scientific formula design and process optimization, while simultaneously meeting diverse needs such as no damage to the mold, a clear water finish, and a delicate feel.1. Film Formation Mechanism: Building a Fundamental Barrier for Efficient ReleaseThe release efficiency of water-based release agents stems from their unique film-forming technology. When the release agent is uniformly coated on the mold surface, the water evaporates rapidly, forming a continuous and dense silicone resin film. This film layer has a dual function: on the one hand, its low surface energy characteristics reduce the adhesion between concrete and the mold by more than 80%, achieving rapid release; on the other hand, the active ingredients in the film layer undergo a weak chemical reaction with cement hydration products, forming a chemical isolation layer, further weakening the interfacial bonding force. The uniformity of the film layer is a key factor affecting release efficiency. The water-based formula, by adding leveling agents and defoamers, allows the release agent to level within 0.5 seconds after spraying or brushing and eliminate surface bubbles within 10 seconds. An engineering case study shows that using the optimized water-based release agent, the demolding time for irregularly shaped molds was reduced from 120 seconds with traditional oil-based agents to 45 seconds, and there was no residue on the mold surface after demolding, allowing for immediate reuse in the next cycle.2. Surface Modification: Creating the Smooth Touch of Fair-Faced ConcreteThe key to achieving a smooth and flat concrete surface lies in the microscopic modification of the mold surface by the release agent. The water-based release agent introduces ultrafine particles and lubricants to form a mirror-like structure on the mold surface. When concrete is poured, these particles embed into the cement paste surface, forming a dense isolation layer that prevents direct contact between cement particles and the mold, thus avoiding the replication of the mold texture. A laboratory comparative test showed that the surface roughness Ra value of concrete using the water-based release agent decreased from 3.2μm to 0.8μm, meeting the standard for mirror-finish concrete. The achievement of a "clear water effect" relies on the chemical stability of the release agent. Water-based systems, by selecting film-forming substances with a neutral pH, avoid reactions with alkaline substances in cement, preventing surface efflorescence or color differences. Simultaneously, the UV absorbers added to the formulation delay film aging, ensuring surface gloss is maintained even after multiple demolding cycles.3. Process Adaptation: Dynamic Control Balancing Efficiency and QualityThe dilutionability of water-based release agents provides flexibility for process adaptation. By adjusting the solids content, different construction methods can be met: high-solids-content formulations are suitable for spraying, forming a uniform film layer of 0.1-0.2 mm; low-solids-content formulations are suitable for brushing, reducing material consumption. A precast component factory's practice shows that diluting the release agent to a 20% solids content reduces the dosage per square meter from 0.2 kg to 0.12 kg, lowering costs by 40%, while demolding efficiency remains unaffected. Key indicators for process control of water-based release agents. The silicone defoamer used in the formulation can break up bubble films within 0.1 seconds, while the dispersant ensures uniform suspension of solid particles, avoiding coating defects caused by sedimentation. In automated production lines, airless spraying of the release agent can be achieved by controlling the spraying pressure and distance, further eliminating the risk of bubbles. After applying this technology to a high-speed railway track slab production line, the product qualification rate increased from 92% to 98%, and the surface porosity defect rate decreased to below 0.5%.Water-based release agents successfully resolve the contradiction between demolding efficiency and surface quality through the synergistic effect of innovative film-forming mechanisms, surface modification technology, and dynamic process control. Its environmentally friendly characteristics align with the trend of green building development, while its comprehensive performance advantages drive the precast concrete industry towards high efficiency and high quality.
