Despite significant progress in corrosion monitoring, accurately targeting critical areas remains a persistent challenge due to irregular textures and environmental variability, which limit the effectiveness of traditional transfer learning approaches. To address this, this study explores the potential of optimised pool-based active learning to enhance corrosion detection. Pool-based active learning prioritises high-value samples, improving segmentation performance while reducing annotation costs by focusing on refining sample selection for corrosion-specific features rather than generic image uncertainty. Two distinct datasets were used to validate the segmentation model rigorously. The first is a laboratory-controlled dataset featuring standardised corrosion samples with precise ground-truth annotations, and the second is a site-realistic dataset captured under real-world environmental conditions. The laboratory experiments were conducted first to validate the methodology under controlled conditions, ensuring accurate segmentation against well-defined corrosion samples, before progressing to the site dataset. Experimental results demonstrate that the DeepLabv3 + model with an EfficientNet backbone, train with batch size of 16 and 50 epochs with an 80% train, 10% validation and 10% test dataset split using the Bayesian Active Learning by Disagreement (BALD) method, achieves 98% ± 0.16% pixel accuracy in controlled laboratory conditions and 87.8% ± 0.98% pixel accuracy on real-world on-site images. Furthermore, the on-site model demonstrated robust segmentation capabilities with a mean Intersection over Union (IoU) of 86.7% ± 0.28%, under challenging conditions. The findings underscore the strengths and trade-offs of active learning in corrosion detection. Future work would explore further optimisation methods to balance accuracy, efficiency, and scalability across diverse operating conditions.
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