The Atmospheric Corrosion Sensor System
A complete, integrated platform — sensors, data acquisition, and predictive modelling software — designed to work together synergistically.
Atmospheric Corrosion Sensor System
The complete atmospheric corrosion monitoring platform combines five sensor types, a purpose-built data acquisition system, and the PACMaN modelling software. Each component is designed to work together, providing not just measurement but understanding — why corrosion is occurring and what conditions are driving it.
Time of Wetness Sensor
Corrosion Sensor
RH & Temp Sensor (SH4xI)
K-Type Thermocouple
Rain Sensor
Integrated System
The sensor system can be used standalone and comes with a copy of the PACMaN software — ideal for internal locations or sites where a power supply is available.
Five sensor types. Each serving a specific purpose.
Corrosion Sensor
Designed by Corrosion Prognostics to measure very low resistances, enabling thicker corroding elements. Detects very small changes in resistance and is used to validate the model for each deployment location. Measures general corrosion only.
Time of Wetness Sensor (TOW)
A galvanic couple sensor with interdigitated gold and cadmium traces. Produces a current proportional to surface wetness coverage — sensitive from totally wet down to deliquescence of just 25 mg NaCl/cm². Used to determine pollutant loading on in-situ structures.
Rain Sensor
A commercial sensor that detects precipitation events. Can be configured to register the known rain quantity sufficient to clean surface pollutants — a critical parameter for understanding when the deliquescence cycle resets.
SH4xI — RH & Temperature
A high-accuracy relative humidity and atmospheric temperature sensor that attaches directly to the DAS enclosure. Provides the atmospheric environment data needed to model deliquescence events and corrosion kinetics.
K-Type Thermocouples
Surface temperature measurement using K-type thermocouples, easily thermally coupled to structures with a fast response to changing temperatures. Surface temperature can differ significantly from atmospheric temperature and directly influences corrosion kinetics.
Validation Coupons
Standard AISI 1010 steel and AA2024-T3 aluminium coupons deployed alongside the sensor system provide independent corrosion measurements for ongoing model validation. Pit analysis uses Keyence VR-5100 3D microscopy to sub-micrometre resolution.
Data Acquisition System (DAS)
The DAS converts analogue sensor outputs into digital data, stores them in onboard memory, and transmits compiled datasets at configurable intervals via an integrated modem — directly to a user-specified email address. No site visit is required to retrieve data.
A backup copy of all data is maintained by Corrosion Prognostics, providing resilience against data loss at the receiving end. The user simply chooses the email address and interval; everything else is handled automatically.
The DAS has been designed with operational simplicity as a primary requirement. The combination of automated data transmission and backup storage means asset managers receive a continuous, reliable data feed with no manual intervention.
PACMaN — Prognostic Atmospheric Corrosion Modeling and Analysis
PACMaN is the Windows desktop application that processes sensor and meteorological data to generate corrosion predictions. It accepts data in standardised .csv or .txt format, allows selection of site type or input of site-specific pollutant data, and produces outputs including pit size distributions and steel weight loss over time.
Site pollutant fingerprints are derived from National Atmospheric Deposition Program (NADP) data, which records the ionic content of rainwater at approximately 400 sites across the US (updated monthly). This ensures predictions reflect the actual chemical environment at each deployment location.
PACMaN can operate diagnostically (understanding past corrosion), in real time (tracking current conditions), and prognostically (forecasting future damage using randomised historical meteorological data).
Learn About the Model
Solar Power System
For assets in remote or off-grid locations — pipelines, rural infrastructure, bridges, offshore structures — the add-on solar power system provides fully self-contained operation with no mains power connection required. The system is designed specifically to match the power requirements of the DAS and sensor suite.
Off-grid deployment
No mains power required — suitable for any remote asset location.
Matched power budget
Designed to exactly match the power requirements of the DAS and full sensor suite.
Continuous operation
Battery storage ensures uninterrupted data capture through low-light periods.
Three components. Configured to your needs.
The sensor system, solar power add-on, and pre-configured laptop are available individually or as a complete bundle. Contact our sales team for current pricing and configuration options.
Includes all sensors, DAS, and PACMaN software. Ideal for sites with mains power available.
Add-on solar system for remote or off-grid deployments where mains power is unavailable.
Pre-configured laptop with installed PACMaN and data download tools. Ready to use from day one.