Real-Time Corrosion Monitoring With TEKTELIC LoRaWAN IoT Solution

Corrosion is one of the most silent—and expensive—threats to modern infrastructure. From underground pipelines to above-ground storage tanks and marine assets, metal surfaces are constantly under attack from their environment. That’s why cathodic protection with LoRaWAN IoT monitoring, is essential for extending the service life of these high-value assets.

Most cathodic protection systems still rely on manual site inspections, scheduled voltage checks, and reactive maintenance. This outdated approach is not only time-consuming and costly, but it also leaves gaps where issues can go undetected for weeks or months.

Fact! The research shows, Annual Corrosion Costs in the U.S.: Corrosion incurs an estimated annual cost of $1.1 trillion in the United States, accounting for over 6% of the nation’s GDP. This figure encompasses both direct costs, such as maintenance and repairs, and indirect costs like downtime and loss of productivity (G2MT Laboratories).

In an age where smart infrastructure is becoming the norm, corrosion protection needs to evolve—and it has.

That’s where LoRaWAN® technology comes in. By enabling long-range, low-power communication between field sensors and central systems. For cathodic protection, this means continuous monitoring—even in remote, buried, or hard-to-access areas.

This article explores how combining Cathodic Protection with LoRaWAN® transforms corrosion monitoring from a reactive task into a proactive, intelligent process. You’ll also see how TEKTELIC’s carrier-grade LoRaWAN® gateways support dependable, large-scale deployments.

What is Cathodic Protection? How Does This Protection Work?

Out of sight doesn’t mean out of danger—especially when it comes to metal infrastructure buried underground or underwater. Corrosion causes billions of dollars in damage every year, slowly weakening pipelines, tanks, and other critical assets until leaks, breakdowns, or environmental disasters force emergency repairs. So how do industries protect themselves from this silent threat?

The answer is a smart but simple method called Cathodic Protection (CP).

To understand how cathodic protection works, it helps to first look at how corrosion happens. When metal—like steel—is exposed to water or moist soil, it starts to break down through a chemical reaction. Tiny electric currents form on the metal’s surface, creating small areas where the metal begins to rust and slowly wears away.

So, what is cathodic protection? It’s a reliable method used to stop this process. Instead of letting the metal corrode, cathodic protection redirects the corrosion to another material—called a “sacrificial anode”—which corrodes in place of the protected metal. In simple terms, one material takes the hit so the important structure stays safe.

Think of it like a bodyguard for steel: one material takes the hit so the critical asset doesn’t have to.

How does it work? Cathodic protection interrupts the process losing part of the metals by supplying electrons from an external cathodic protection power supply, forcing the entire metal surface to become the cathode in the reaction—which doesn’t corrode.

There are two main strategies to do this. Let’s take a look at the key differences between these approaches.

This table can help you quickly understand which method is better suited to your specific application and help to make a practical decision.

Cathodic protection offers a time-tested and scientifically sound method to safeguard critical infrastructure. Whether through sacrificial anodes or impressed current systems, it’s about choosing the right strategy to protect your investments beneath the surface.

Why Corrosion Protection Is No Longer Optional

For large-scale infrastructure operators – whether in oil & gas, utilities, water management, or marine transport—the absence of reliable corrosion protection isn’t just a technical oversight. It’s a high-risk liability.

Here are some of the most frequently occurred challenges that companies face:

1. Unexpected Failures and Downtime. Without efficient system of the cathodic protection, corrosion can silently degrade pipelines, tanks, and structural supports. By the time signs of failure appear—leaks, cracks, or collapses—it’s often too late to avoid costly unplanned outages and emergency repairs.
2. Environmental and Safety Hazards. Leaking pipelines or tanks can result in hazardous spills, groundwater contamination, or even explosions. These events don’t just cause financial damage—they can lead to regulatory fines, lawsuits, and long-term brand harm.
3. Increased Maintenance and Inspection Costs. In the absence of automated corrosion monitoring, operators must rely on frequent manual inspections. These are labor-intensive, expensive, and often reactive rather than preventive—catching issues after damage has already occurred.
4. Reduced Asset Lifespan. Infrastructure that’s allowed to corrode unchecked deteriorates much faster. What could have been a 40-year asset may require replacement in half the time, doubling your capital expenditure and disrupting long-term planning.
5. Compliance and Regulatory Risk. Many jurisdictions mandate corrosion protection for critical assets, especially in oil & gas and water sectors or sectors with underground metal objects . Failure to implement adequate systems can result in non-compliance penalties and project shutdowns.

These challenges highlight a simple truth: corrosion doesn’t just damage infrastructure—it erodes budgets, safety, and operational confidence.

With the rise of low-power wide-area networks, operators no longer have to choose between performance and practicality. in the following chapter, we’ll explore how LoRaWAN® IoT solutions are transforming cathodic protection—from isolated systems to intelligent, real-time networks that protect assets more effectively and efficiently than ever before.

LoRaWAN® IoT Solutions for Cathodic Protection

Traditionally, CP systems operated in isolation. Technicians had to visit each test station to collect readings—a slow, costly, and error-prone process. LoRaWAN® changes that:

• Real-Time Monitoring: CP sensors stream voltage, current, and performance data 24/7.
• Event-Driven Alerts: Automatic notifications when thresholds are breached.
• Battery Efficiency: Devices operate for up to 10 years without replacement.
• Long-Range Communication: Data reaches gateways several kilometers away—even from buried or remote locations.
• Centralized Data for Smart Decisions: Historical analysis, predictive insights, and compliance reporting—all in one place.

LoRaWAN® transforms cathodic protection from a static, isolated process into a dynamic, data-driven system. What was once limited to periodic manual inspections is now a real-time, intelligent network of sensors and gateways that constantly monitor corrosion protection levels—reducing risk, optimizing maintenance, and extending asset life.

But realizing the full potential of remote CP monitoring requires more than just a wireless protocol. It demands a network infrastructure that’s built to last, performs consistently in harsh environments, and integrates seamlessly with existing systems.

This is where TEKTELIC stands apart—as a globally recognized provider of Complete End-to-End LoRaWAN® Solutions. Known across industries for its carrier-grade, ultra-reliable gateways, TEKTELIC delivers the performance and durability required for mission-critical applications like cathodic protection. With a portfolio designed specifically for challenging field conditions—whether it’s a buried pipeline in the Canadian north or a tank farm in the Middle East—TEKTELIC ensures that your LoRaWAN® deployment is not only connected, but engineered for long-term success.

Reliable Corrosion Control Starts with Carrier-Grade LoRaWAN® Gateways

Deploying a LoRaWAN®-enabled cathodic protection system starts with choosing the right network foundation. The gateway connects your wireless sensors in the field to the platforms where data is analyzed and decisions are made. For infrastructure operators, selecting the right gateway plays a key role in how well your corrosion protection strategy works—especially in remote or challenging environments.

TEKTELIC offers a comprehensive lineup of gateways designed to meet the needs of any deployment, from small off-grid sites to large-scale industrial operations.

1. KONA Photon: Solar-Powered Gateway for Remote Deployments

The KONA Photon is a solar-powered, 8-channel LoRaWAN® gateway designed for autonomous remote deployments. Its zero-footprint design and IP67 rating make it ideal for challenging environments where traditional power sources are unavailable. With a 100-hour internal battery and integrated 3G/4G modem, it ensures continuous operation of cathodic protection sensors in off-grid locations.

2. KONA Mega: High-Capacity Gateway for Industrial Applications

The KONA Mega gateway is a carrier-grade solution supporting up to 12 million messages per day. Its full-duplex capability and multiple Rx and Tx channels make it ideal for industrial applications requiring high data throughput. The environmentally hardened aluminum enclosure ensures durability in extreme conditions, making it a reliable choice for extensive CP sensor networks.

3. KONA Mega Ex: Rugged Gateway for Explosive Atmospheres

The KONA Mega Ex gateway is designed for ATEX Zone 2 environments, offering full-duplex operation and multiple Rx and Tx channels. Its IP67 rating and rugged design make it suitable for deployment in explosive atmospheres, such as oil and gas facilities, where robust corrosion control is critical.

4. KONA Macro: Scalable Solution for Outdoor Installations

The KONA Macro gateway offers a scalable and cost-effective monitoring solutions for outdoor CP monitoring. Its IP67-rated enclosure and integrated cellular modem provide reliable connectivity in harsh conditions. With support for 16 Rx / 2 Tx channels and integrated GPS, it’s well-suited for large-scale corrosion control deployments across pipelines and infrastructure networks.

5. KONA Macro Ex: Certified for Hazardous Environments

Designed for ATEX Zone 1 hazardous locations, the KONA Macro Ex gateway ensures safe and reliable operation in environments with combustible gases or vapors. Its robust enclosure is optimized for airflow and heat dissipation, making it suitable for chemical plants and other high-risk areas requiring stringent corrosion control measures.

Wondering how to choose the best gateway for your specific use case? No worries, our experts have already gathered the best options on the market in the blog-post article “How to Choose the Right Industrial IoT Gateway: 16 Answers to Help You Pick the Best Option“

Key Benefits of Using LoRaWAN® in Cathodic Protection Systems

1. Coverage Across Remote and Buried Assets. LoRaWAN® signals can travel 10+ kilometers in rural areas, penetrate through buried vaults, and operate reliably in areas without cellular or fiber infrastructure.

2. Early Detection of Failures. Event-based alerts and remote monitoring enable early warnings when protection levels drop or anomalies occur. This helps prevent costly corrosion-related failures by allowing proactive maintenance, rather than reacting after damage is done.

3. Seamless Integration with Digital Twins and SCADA. Modern LoRaWAN® deployments can feed directly into cloud-based analytics platforms, digital twins, or existing SCADA via MQTT or RESTful APIs. CP data can be analyzed alongside pressure, flow, or asset inspection data, enabling multi-layered risk analysis and smarter planning. With gateways like those from TEKTELIC, you can deploy alongside current infrastructure without major retrofits.

4. Enabling Predictive Maintenance. With time-series data from LoRaWAN® wireless sensor, machine learning models can detect patterns that precede CP system degradation—helping schedule repairs before failures occur. Wireless sensor network reduces unplanned outages, saves money on emergency response, and supports a proactive maintenance culture.

5. Scalable for Any Environment. Whether it’s a short urban pipeline or a multi-region energy distribution network, LoRaWAN® supports thousands of connected wireless sensors over long distances—even in remote or underground environments.

6. Long Battery Life and Low Power Consumption. LoRaWAN® devices are designed for extreme efficiency, with 5–10 years of battery life common for CP sensors. This means lower maintenance frequency and more reliable long-term remote monitoring in harsh or inaccessible environments.

7. Enhanced Worker Safety. Monitoring hazardous environments remotely reduces the need for technicians to enter confined spaces, high-voltage areas, or explosive zones—especially when paired with ATEX-certified devices and gateways.

Conclusion

In corrosion control, the stakes are rarely visible—until failure makes them impossible to ignore. Cathodic protection remains a proven defense, but its effectiveness depends on more than just proper installation. It relies on continuity, awareness, and timely action.

LoRaWAN® doesn’t replace cathodic protection—it elevates it. By enabling real-time visibility, wireless data capture, and intelligent analysis, LoRaWAN® makes corrosion a problem you can see—and solve—before it becomes failure.

This shift doesn’t happen overnight. But for organizations managing critical infrastructure—pipelines, storage tanks, water systems—the path forward is becoming clearer. Remote monitoring, scalable wireless networks, and reliable platforms like TEKTELIC’s allow corrosion protection to evolve alongside the complexity of the assets it safeguards.