Formulation Optimization and Comprehensive Performance Evaluation of Waterborne Acrylic Road Marking Paints via Orthogonal Experiment and Weighted Comprehensive Scoring

Conventional solvent-based and hot-melt road marking paints face significant challenges regarding high volatile organic compound (VOC) emissions and limited durability, necessitating the development of eco-friendly, high-performance alternatives. In this study, a waterborne acrylic road marking paint was systematically formulated and optimized using an L16(45) orthogonal experimental design coupled with a comprehensive weighted scoring method integrating subjective and objective (entropy) weights. Four key formulation parameters (pigment-to-binder ratio, titanium dioxide content, ground calcium carbonate content, and coalescing agent dosage) were investigated, with abrasion resistance, hiding power, luminance factor, and stain resistance as evaluation criteria. The optimized formulation was identified through range analysis of comprehensive scores and subsequently subjected to rigorous performance characterization, including retroreflectivity optimization, Taber and accelerated abrasion testing, UV-accelerated weathering, skid resistance, and VOC emissions measurement using a self-designed sealed chamber system. Benchmark comparisons against commercial waterborne and hot-melt paints demonstrated that the developed formulation achieves superior abrasion resistance, exceptional weatherability, and meaningfully lower VOC emissions. Field application on an operational highway section in Liaoning Province, China, confirmed the practical constructability and performance reliability of the optimized paint under real-world construction conditions. This research provides both theoretical guidance and practical validation for the design of sustainable, durable, and highly visible road marking materials, contributing to the advancement of environmentally responsible transportation infrastructure.