April 1, 2026
New sensing technology strengthens corrosion testing for Australian steel
A new sensing capability developed through a partnership between the ARC Steel Research Hub, the University of Wollongong and BlueScope Steel is reshaping how corrosion is monitored in both laboratory and outdoor environments. The project, originally led by Dr Cormac Fay, was completed by UOW’s Elliott Pilton with industry guidance from BlueScope’s Dr Thomas Jurak. They set out to modernise earlier work by upgrading sensors, integrating LoRa (long-range) wireless communications and creating both laboratory and field-ready versions of the monitoring system.
At the centre of the work is BlueScope’s Bellambi Point exposure site, where the monitoring system will track corrosion on steel panels directly in a marine setting by recording temperature, humidity and surface wetness in real time, providing a clear picture of what coated steel products experience in harsh coastal conditions. The same sensing approach has also been deployed inside BlueScope’s accelerated corrosion chambers within their Weathering Laboratory at Port Kembla, allowing researchers to more accurately replicate outdoor conditions and directly compare lab-based predictions with real‑world performance. This alignment strengthens confidence in corrosion testing and improves the reliability of product performance forecasts.
The team designed a robust, economical sensing platform built from commercially available components, refined through continuous feedback from industry partners. The result of this iterative approach is a system that is easier to use, more durable and capable of handling data more effectively. It supports faster testing cycles, provides deeper insight into corrosion behaviour and helps establish stronger foundations for future research platforms.
One other significant outcome of the project has been workforce development. After completing the project, Elliott Pilton joined BlueScope, in their Product Innovation and Technology department where his skills and expertise will continue to benefit industry and future sensor innovation.
The technology is already influencing BlueScope’s work, supporting verification of accelerated testing, feeding into Project 3.1’s parallel modelling and validation activities, and contributing to long‑term monitoring of coated products.
Across the broader industry, the system offers new opportunities to more accurately monitor environmental conditions that drive corrosion, improve modelling and forecasting, strengthen corrosion testing standards and build a clearer understanding of corrosive environments. The project stands as a strong example of industry‑focused research delivering practical tools and advancing Australia’s steel innovation capability.