Corrosion is often called the silent destroyer—a slow, invisible process that quietly eats away at the infrastructure we depend on every day. From bridges and pipelines to water systems and storage tanks, the impact of corrosion is far-reaching. A landmark study by the U.S. Federal Highway Administration revealed just how serious the problem is, estimating that corrosion costs the U.S. economy an astonishing $276 billion each year. That’s more than 3% of the nation’s GDP.

A significant share of this burden falls on infrastructure. Highways, bridges, and utility systems alone account for over $22 billion in direct corrosion-related expenses annually. Highway bridges, in particular, suffer heavily—approximately 15% are considered structurally deficient due to corroded steel or reinforcement. Gas and liquid transmission pipelines are another major concern, with corrosion responsible for most of the $7 billion in annual maintenance and monitoring costs. Aging HAZMAT storage tanks and deteriorating water and sewer systems add billions more to the toll.

Despite the massive expense, what’s perhaps most alarming is that much of this damage is preventable. The study concluded that up to 30% of these costs could be saved through better corrosion management practices. This finding underscores a major shift in thinking: corrosion isn’t just a maintenance issue—it’s a data and planning problem.

At Pulse IoT Technologies, we’re helping infrastructure owners make that shift. Our embedded sensor systems are designed to detect the earliest signs of corrosion long before it becomes visible or damaging. Installed during construction or retrofitted into existing structures, our sensors monitor environmental conditions and electrochemical changes in real time, providing asset owners with a powerful tool for predictive maintenance.

By continuously collecting data from within the structure itself, our technology allows engineers to move away from reactive repairs and instead make informed, timely decisions about when and where intervention is actually needed. The result? Lower lifecycle costs, fewer failures, extended asset life, and ultimately, safer, more sustainable infrastructure.

Corrosion will always be a reality. But with the right tools and strategies, its impact doesn’t have to be. At Pulse, we believe that the key to managing corrosion is not just about fighting decay—it’s about unlocking insight. Because when you can see what’s happening inside your infrastructure, you can protect it better, longer, and smarter.

This blog draws on findings from the comprehensive study “Corrosion Costs and Preventive Strategies in the United States”, published by the U.S. Federal Highway Administration and NACE International. The full report is available as FHWA-RD-01-156.