Lifecycle Cost Analysis for Water Infrastructure: Choosing the Right Coating

Lifecycle cost analysis (LCCA) is an important part of the decision-making process. This framework encourages you to move beyond upfront price tags and understand the long-term cost implications of various coating systems for your water and wastewater assets.

With the right data and perspective, it’s clear that investing in high performance protective coatings, like those from Sherwin-Williams, can offer superior value—not just in dollars but also in operational resilience and peace of mind.

Lifecycle Cost Analysis (LCCA)

Making decisions based solely on upfront price often overlooks the long-term performance and reliability of infrastructure solutions. Lifecycle cost analysis shifts the focus to a more holistic view, helping water and wastewater utilities make smarter, more sustainable investments.

What Is LCCA?

Lifecycle cost analysis is a comprehensive approach to evaluating the total cost of a product or system over its entire useful life. Unlike conventional cost comparisons that focus solely on initial price, LCCA accounts for financial implications from acquisition to disposal.

Total Cost of Ownership Factors 

In the context of water infrastructure coatings and linings, total cost of ownership includes the cost of the coating product, application labor, surface preparation, cure times and safety measures. It also factors in ongoing maintenance, inspection, potential downtime and the expected service life of the system.

The sum of these factors paints a fuller, more accurate picture of value.

The Importance of LCCA in Water and Wastewater Infrastructure

Water and wastewater systems are mission-critical and constantly exposed to aggressive environments. Coatings and linings that account for these variables can drastically improve long-term outcomes.

Evaluating lifecycle cost is an important part of maximizing infrastructure investments.

Environmental Challenges and Cost Implications

Water and wastewater systems operate in demanding conditions. Continuous exposure to water, chemicals, temperature fluctuations and microbial activity can erode even the strongest materials. These environmental stressors accelerate corrosion and structural degradation, which increases the urgency for reliable protective solutions.

Coatings that can resist these stressors—like high-performance epoxies and polyurethanes—minimize surface breakdown and prolong system life.

Budget Constraints and Long-Term Risks

Infrastructure managers are often forced to make budget-conscious decisions. Unfortunately, when coating systems fail prematurely, the repercussions can far exceed the savings gained from selecting a lower-cost solution.

Repair work is costly, emergency downtime disrupts operations and regulatory penalties can mount quickly. Alternatively, investing in long-lasting coating systems reduces the frequency and scope of interventions, keeping budgets more predictable over time.

LCCA as a Strategic Tool

By using LCCA to evaluate coating options, municipalities can shift their strategy from reactive to proactive. Rather than chasing short-term savings, they can prioritize systems that deliver long-term protection, reduce total ownership costs, and ensure long-term regulatory compliance. Coatings that meet or exceed regulatory standards also help maintain compliance and limit unplanned expenditures.

In this context, performance and longevity become critical components of fiscal responsibility.

Hidden Costs of Low-Quality Coatings and Linings 

Cheap coatings may offer attractive bids, but they often lead to long-term financial, operational and environmental liabilities. These hidden costs are frequently overlooked until they become unavoidable and expensive.

Frequent Recoatings & Downtime

Initial cost is often a driving factor in coating selection, but it can be misleading. Low-cost coatings may lack durability, chemical resistance or adhesion strength. While the upfront savings are appealing, these systems often require frequent recoating.

As a result, each cycle compounds labor costs, downtime and disruption. In water and wastewater applications, this process could mean repeatedly draining tanks or shutting down treatment systems to repair degraded linings.

Structural Damage and Infrastructure Loss 

When a coating fails to protect against corrosion, the damage to the underlying infrastructure can be irreparable. In extreme cases, municipalities may be forced to replace entire sections of pipe, structural components, tank linings or concrete basins.

The cost of these failures far outweighs the investment in a more robust coating from the outset, as rehabilitating concrete or replacing corroded steel is both time-consuming and capital intensive.

Operational Downtime and Service Interruptions

Frequent maintenance cycles and emergency repairs can take systems offline, which impacts service delivery and public trust. Repeated service disruptions due to poor coating performance can erode public confidence and reduce system efficiency.

High-performance coatings reduce these risks by extending service intervals and preserving asset integrity.

Liability and Insurance Impact

Unexpected failures resulting from inferior coatings can increase liability exposure and raise insurance premiums. In some cases, they can result in claims or litigation. Using trusted, high-quality coatings can reduce these risks and contribute to more favorable long-term coverage terms.

Why Invest in High-Quality Coating and Lining Systems? 

High-performance coatings go beyond aesthetics or surface protection. They are strategic tools for risk reduction, asset preservation and operational efficiency in water and wastewater applications.

Extend the Life of Critical Assets 

High-performance coatings serve as durable shields against corrosion, erosion and chemical attack. When properly selected and applied, they protect the underlying infrastructure for decades, reducing the need for disruptive and expensive maintenance.

This extended service life is particularly valuable in water and wastewater systems where service continuity is critical. A longer-lasting lining translates directly into fewer shutdowns and fewer capital replacements.

Avoid Catastrophic Failures 

When coatings fail, the consequences can be severe.

Blistering, peeling or delamination exposes substrates to aggressive environments, accelerating corrosion and compromising the integrity of the asset. The real cost of such failures goes far beyond the coating itself.

A high-performance lining acts as a first line of defense against these costly events.

Lower Maintenance and Operational Costs

With longer-lasting protection, facility managers can extend maintenance intervals, reduce labor hours and avoid costly system shutdowns. Fewer recoating cycles over the asset’s life mean fewer disruptions, more efficient operations and a better return on investment. High-performance coatings help extend that interval significantly.

Preserve System Uptime

Unplanned outages can create cascading problems, from boil orders to untreated wastewater discharges. Durable coatings reduce the likelihood of failure-induced shutdowns, which improves reliability and reduces both financial and societal costs.

Contribute to Sustainability and Environmental Goals

High performance coatings also contribute to broader environmental and sustainability goals. Longer-lasting coating systems reduce the need for frequent recoating, which in turn minimizes the use of raw materials, energy consumption during application and waste generation.

Over the lifecycle of a water or wastewater asset, the environmental impact of maintenance cycles—including volatile organic compound (VOC) emissions, hazardous waste disposal and energy use—can be significant. By choosing durable, low-leaching coatings that comply with rigorous environmental standards, utilities can reduce their overall environmental footprint.

6 Key Considerations When Selecting a Coating System

Selecting the optimal coating system requires a full understanding of the conditions, constraints and long-term goals associated with the application. A coating that’s ideal for one project may be unsuitable for another.

Consider these critical variables as you evaluate your options and make your decision.

1. Matching the Environment and Substrate 

Choosing the right coating begins with a thorough understanding of the operating environment. Is the surface submerged or exposed to UV? Will it encounter acidic wastewater or abrasive solids? Factors like pH, moisture levels, chemical exposure and microbial activity play a critical role in determining coating performance.

Additionally, the substrate itself—be it concrete, steel or ductile iron—requires a compatible system to ensure proper adhesion and performance.

2. Application Constraints

Environmental and logistical conditions at the jobsite can influence the feasibility of certain coating systems. Temperature, humidity and required cure times must be considered.

Fast-curing options might be ideal for short maintenance windows, while others require controlled environments to achieve optimal results. In some cases, coatings must be applied in tight or confined spaces, which adds further complexity to the selection process.

3. Regulatory Compliance and Performance Goals

The selected coating should not only meet performance expectations but also align with health, safety and environmental standards. Long-term compliance and inspection-readiness depend heavily on these initial choices.

For example, coatings used in potable water systems must meet standards like NSF/ANSI 61. In wastewater settings, coatings and linings with resistance to hydrogen sulfide and microbial-induced corrosion is vital.

4. Ease of Inspection and Monitoring

Some coatings are formulated with features that make it easier to detect early signs of wear or failure, such as color change indicators, contrasting primer layers or enhanced UV visibility. These visual cues provide facility operators and inspectors with clear, early warnings that maintenance is needed before more significant damage occurs. 

In water and wastewater systems, where early intervention can prevent service disruptions and costly remediation, this capability is especially valuable. Coatings that simplify inspections help utilities maintain uptime while improving long-term reliability.

5. Contractor Expertise and Application History 

Even the most advanced coating systems depend on proper surface preparation and expert application to perform as intended. It’s not enough to select a high-quality product. Application technique, environmental control and curing conditions are all critical to success.

When evaluating coating systems, it's important to verify that contractors have hands-on experience with the chosen product and that the manufacturer can provide case studies or references from similar installations.

6. Repairability and Long-Term Flexibility 

Infrastructure maintenance is inevitable, but coatings that can be easily repaired in place offer significant long-term savings. Systems that allow for touch-up, overcoating or partial patching without full removal reduce labor and material costs while minimizing operational disruption.

This benefit is particularly important for water and wastewater systems where draining assets or shutting down operations can be both logistically complex and financially burdensome. Selecting coatings with flexible maintenance options ensures that minor issues don’t escalate into major rehabilitation projects, ultimately preserving system integrity and reducing lifecycle costs.

Comparing Coating Systems Through the Lens of LCCA

When coating and lining systems are compared not just by material price but also by total lifecycle cost—including maintenance frequency, performance longevity and risk reduction—higher-quality systems almost always prove to be the more economical and reliable choice. Field-tested systems with extended service life and fewer recoating requirements create value that extends far beyond initial bid comparisons.

Start by reviewing these common types of coatings and linings used in water and wastewater infrastructure through the lens of lifecycle cost.

To calculate lifecycle cost for protective coating systems, you begin by determining the total applied cost of each coating system, which includes material, labor, surface preparation, and application costs. Then, divide that total by the expected service life of the system to get a cost per year. This provides a straightforward comparison of different systems based on durability and cost-effectiveness.

Shop the Best Water Infrastructure Coating and Lining Solutions at Sherwin-Williams

In water and wastewater infrastructure, short-term savings often result in long-term liabilities. By applying lifecycle cost analysis, utilities and municipalities can uncover the hidden risks and expenses that come with inferior coatings and instead invest in solutions that preserve infrastructure, support public safety and reduce operational burdens.

High performance coatings and linings from Sherwin-Williams are engineered specifically for the demands of the water and wastewater sector. Backed by deep technical expertise and decades of proven results, these systems offer proven protection and peace of mind.

To make the most informed and cost-effective decision for your infrastructure, contact a Sherwin-Williams expert today. We’ll help you design a tailored solution to help you safeguard your assets—and your budget—for years to come.