Aging Water and Wastewater Infrastructure: How to Address the Rehabilitation of Tanks

Replacing these massive assets can be cost-prohibitive and logistically disruptive. That’s why tank rehabilitation has emerged as a vital strategy—not only for maintaining operational integrity but also for advancing sustainability goals. By extending the life of existing infrastructure, utilities and facility managers can reduce material waste, minimize carbon footprints, and avoid the environmental impact of full-scale replacements.

At Sherwin-Williams, we are a leader in protective coatings and linings for the water and wastewater industry.  Our mission is to help extend the service life of aging tanks through innovative, sustainable, high-performance solutions. . With the right products and a proactive approach, organizations can rehabilitate aging tanks to meet current performance and regulatory standards- while supporting long term envrionmnetal stewardship and fiscal responsibility and avoiding the expense and complications of full replacement.

Common Concerns with Failing Water Tanks

Aging water tanks are susceptible to a variety of issues that compromise both performance and safety. As time passes, even the most well-constructed tanks begin to show signs of deterioration due to a combination of chemical exposure, fluctuating weather conditions and natural material fatigue.

Addressing these concerns early is essential to avoid costly repairs, ensure compliance with regulatory standards and prevent failures that could affect water quality, public health or operational uptime.

Corrosion and Structural Integrity 

One of the most pressing concerns with aging water tanks is the corrosion of steel components and the weakening of structural supports.

When metal surfaces are left unprotected or when coatings degrade, exposure to oxygen and moisture accelerates rust formation. Over time, this corrosion can reduce wall thickness, compromise load-bearing capacity and lead to safety hazards.

Even concrete tanks are not immune; while concrete tanks are often perceived as more durable than steel, they are not immune to deterioration. Over time, environmental exposure, chemical attack, and structural stress can significantly compromise their integrity. Concrete tanks are reinforced with steel rebar, which is vulnerable to corrosion when moisture and oxygen penetrate the concrete. As rebar corrodes, it expands, causing internal pressure that leads to spalling—the flaking or breaking off of concrete surfaces. This not only weakens the structure but also exposes more steel to corrosive elements, creating a vicious cycle. Older concrete tanks may not meet modern seismic or structural standards. Over time, even well-built tanks can suffer from loss of alkalinity, shrinkage and creep.

Liner Degradation and Leakage

Tank and reservoir liners serve as a barrier between the tank walls and the water they contain, but they’re not immune to aging. Over time, mechanical stress, temperature fluctuations and chemical interactions can cause liners to blister, crack or delaminate. When this happens, leaks become more likely—leading to water loss, contamination risks and even undermined foundations.

Early signs of liner failure are often subtle, but if ignored, they can escalate into major repairs.

Health and Safety Compliance Issues

Regulations for water quality and tank safety evolve over time, and older tanks may not meet current standards. Common issues include sediment accumulation, biofilm development and deteriorating coatings that can leach into stored water.

These problems pose serious risks, particularly for potable water tanks serving public utilities. Compliance failures can result in fines, service interruptions or even liability concerns.

Rising Costs from Deferred Maintenance

Putting off minor repairs may seem cost-effective in the short term, but over time, the damage compounds, turning manageable issues into expensive emergencies.

Deferred maintenance often results in extended downtime, emergency contractor rates and even full tank shutdowns. Furthermore, as deterioration accelerates, more extensive structural repairs may become necessary.

The Challenges of Aging Water and Wastewater Infrastructure

The struggle to maintain aging infrastructure is shaped by physical deterioration, budgetary limits, environmental stressors and operational logistics. Facilities often need to keep water systems operational even while undergoing maintenance, which creates a balancing act between urgent rehabilitation needs and uninterrupted service. Add in regulatory oversight and climate-related variables, and it becomes clear why addressing aging infrastructure is both a technical and administrative challenge.

Recognizing these factors can help guide smarter planning and resource allocation.

Budget Constraints 

Funding limitations are one of the most consistent barriers to infrastructure improvements. Many municipalities operate on tight budgets, leaving little room for major capital investments like tank replacement. As a result, maintenance is often delayed or performed piecemeal, which ultimately increases overall costs.

Rehabilitation offers a middle path, addressing critical issues without the full expense of new construction.

Environmental Exposure 

Water tanks face relentless environmental stress.

UV radiation from the sun degrades coatings over time, leading to chalking, embrittlement and eventual failure. Humidity and freeze-thaw cycles expand and contract tank surfaces, exacerbating coating cracks and allowing moisture intrusion. In wastewater environments, chemical exposure adds another layer of attack: Corrosive gases and liquids can break down protective linings quickly if not properly formulated.

Each environmental factor contributes to accelerated degradation unless specifically addressed through material selection and application technique.

Service Disruptions

Taking a water tank offline for maintenance is often a logistical nightmare, especially in high-demand or emergency service areas. Utilities must carefully schedule shutdowns to avoid interruptions to homes, businesses or industrial operations. Short windows for maintenance mean that every hour counts, and delays can have ripple effects on service delivery.

That’s why rehabilitation solutions that offer rapid cure times, minimal surface prep or even in-service application options are especially valuable. These solutions reduce downtime and help ensure continuity of operations.

Lack of Early Warning 

Unlike a leaky pipe, a degrading tank may not show obvious signs until it's too late.

Deterioration often happens beneath the surface—within coatings, behind liners or in submerged metal sections where visual inspections are difficult. Without regular evaluations issues can remain hidden until a critical failure occurs. Regular evaluations of water infrastructure—especially those with hidden or submerged components—require specialized tools and techniques to detect deterioration early and accurately such as ultrasonic thickness gages and holiday detectors (spark testing).

Unfortunately, by that time, damage is often extensive and costly to repair. Implementing a system of routine diagnostics and data tracking can provide the early warnings needed to act before disaster strikes.

What Is the Role of Preventive Maintenance? 

Preventative maintenance is a vital component of asset preservation that can dramatically extend the operational life of water tanks. By staying ahead of problems and investing in proactive solutions, utilities can reduce unplanned repairs, control operational costs and ensure safe service delivery.

Routine maintenance programs create a culture of stewardship and accountability that benefits the organization and the communities it serves. The key is consistency, planning and the right rehabilitation products.

Conducting Routine Inspections and Documentation

Regular inspections—ideally scheduled annually or biannually—allow facility managers to track the condition of tanks over time. These inspections may include visual checks, ultrasonic thickness testing or interior camera evaluations.

Detailed documentation creates a historical record, which helps teams understand trends and predict future needs. It also supports compliance with inspection mandates from regulatory bodies.

Implementing Predictive Maintenance Planning

By leveraging data gathered during inspections, utilities can develop predictive maintenance models that anticipate failures before they occur.

The preventative maintenance approach moves beyond reactive repairs and into strategic asset management. Software tools can help schedule maintenance at optimal intervals, forecast coating degradation timelines and prioritize spending based on risk. The result is a more efficient use of resources and less emergency work.

Predictive planning also supports better decision-making at the administrative level.

Acting Early with Proactive Repairs 

Addressing minor defects early prevents them from becoming costly disasters. For example, a small patch of corrosion today could evolve into a large-scale structural problem within months if ignored. Early action may involve touch-up coatings or spot repairs to prevent further damage.

These relatively inexpensive interventions can add years to a tank’s life. In contrast, waiting until damage is widespread often requires full recoating or structural work.

Extending Service Life Through Maintenance Investment

Preventative maintenance should be treated as an investment and strategic priority, not an afterthought. When tanks are inspected regularly and maintained properly, their lifespan can exceed design expectations. This process not only saves money in the long run but also reduces environmental waste and resource use.

Coatings selected for durability and chemical resistance can further stretch the timeline between rehabilitations.

Why High Performance Coatings and Linings Are the Cornerstone of Successful Tank Rehabilitation

When it comes to rehabilitating aging water tanks, the coating system you choose makes all the difference. These systems are designed to combat corrosion, resist environmental stressors and meet stringent regulatory standards, and support long-term sustainability by extending asset life and reducing the need for resource- intensive replacements.

Choosing the right coating ensures performance, safety and cost-efficiency over the long haul.

They Deliver Maximum Corrosion Resistance

Corrosion is the silent enemy of every water tank, quietly compromising steel integrity over time. Investing in advanced corrosion-resistant products is essential for preserving structural performance.

High performance coatings form a barrier that isolates the substrate from moisture and corrosive agents. Some systems include sacrificial elements like zinc to add an extra layer of protection. These coatings prevent rust before it starts, helping extend service life dramatically.

They Minimize Downtime with Fast-Return Systems

Every day a tank is out of service affects customers, operations, or production schedules. That’s why fast-cure, moisture-tolerant and 100% solids epoxy coatings, are invaluable—enabling rapid return to service while delivering long-term protection against corrosion and environmental stressors. . These formulations allow tanks to return to service sooner, even in challenging conditions. Rapid installation reduces labor costs, shortens shutdown windows, and keeps utility schedules on track.

They Offer Tailored Formulations for Every Environment

No two tanks are the same. Whether it’s a cold-climate potable water tank, a high-humidity wastewater facility or a tank exposed to aggressive chemicals, find a coating and lining system designed to meet that challenge.

Ensure compatibility with substrate materials, application methods and service conditions. This precision ensures optimal performance and long-term reliability.

They Back Claims with Proven Field Results

Performance matters, but so does proof.

Choose coatings that have been field-tested in real-world applications across a wide range of industries and climates. Look for case studies, performance data and testimonials that confirm the long-term effectiveness of these systems.

Utilities and municipalities rely on coatings and linings to protect their most critical infrastructure assets, so find a partner with a track record of results.

Coating and Lining Restoration for Aging Water Tanks: 4 Steps to Follow

When inspections reveal signs of aging, damage or deterioration, selecting the appropriate restoration technique is vital.

Rehabilitation isn’t one-size-fits-all; different tank conditions, service requirements and operational constraints call for different solutions. From a touch-up to a total overhaul, the goal remains the same: to restore integrity, protect assets and extend lifespan.

1. Prepare the Surface and Clean Contaminants

Surface preparation is the foundation of every successful coating job. It involves removing rust, failing coatings, contaminants, oils and debris, to create a clean substrate that will bond well with the new system. Depending on the condition of the tank, this process may involve pressure washing, solvent cleaning or abrasive blasting.

Inadequate surface prep is one of the most common causes of premature coating failure. Investing time and resources here ensures long-term adhesion and effectiveness.

2. Repair and Patch Structural Deficiencies

Ignoring structural issues can lead to coating delamination or accelerated degradation. So, before applying a new coating, any underlying damage must be addressed. Solutions might include welding cracked joints, filling pits, replacing corroded metal sections or repairing leaks.

Additionally, keep in mind that repairs must be compatible with both the substrate and the coating system. Thorough prep and patching give coatings a solid base for performance.

3. Select the Right Coating System for the Environment

Different water types, temperatures and contaminants demand tailored coating and lining systems. Selecting the wrong product can result in early failure and safety concerns.

For example, when it comes to potable water, NSF/ANSI/CAN 61 certification is non-negotiable. Alternatively, wastewater tanks may require high chemical resistance to withstand hydrogen sulfide or other aggressive agents.

4. Apply New Protective Coatings and Linings

Once repairs are complete, applying a high-performance protective system is essential to shield the tank from future damage. Depending on the tank’s purpose, epoxy, polyurethane, polysiloxane, fluoropolymer  or zinc-rich coatings may be used. These coatings act as barriers to moisture, chemicals and mechanical abrasion.

Modern systems are engineered for rapid cure times, allowing quicker return-to-service. Proper application techniques and environmental controls ensure maximum durability.

Additional Considerations in Tank Rehabilitation

For a successful restoration project, every step of the process must align with safety, compliance and performance standards. Environmental regulations, workforce qualifications and other outside factors play a major role in whether a project succeeds or falls short.

Understanding and planning for these considerations upfront reduces risk and improves outcomes. The good news is that thorough preparation helps protect not only your tank but also your budget and your people.

Regulatory and EPA Compliance

Rehabilitation projects must align with stringent regulations set forth by the Environmental Protection Agency (EPA) and local water authorities, which includes using coatings that are approved for contact with drinking water, adhering to volatile organic compound (VOC) restrictions and properly managing waste disposal.

Staying ahead of compliance requirements reduces long-term legal and operational risks. Failure to comply can result in hefty fines and project delays, while selecting approved coating systems and working with experienced vendors ensures smoother approvals.

Experienced Contractors

The skill level of the applicator can make or break the performance of a coating system.

Experienced contractors are trained in surface prep, material handling, application techniques and safety practices. Their expertise ensures coatings are applied at the correct thickness, under the right environmental conditions and with full documentation.

Hiring an experienced team reduces the risk of premature failure and ensures the project stays on schedule. And trusting trained professionals is a smart insurance policy for your investment.

Proper Safety Protocols on the Job Site

Tank rehabilitation often involves confined spaces, elevated work platforms and exposure to hazardous materials. Safety procedures must be in place to protect workers and comply with Occupational Safety and Health Administration (OSHA) requirements such as personal protective equipment (PPE), fall arrest systems, ventilation plans and emergency protocols.

A safe site is an efficient site. Accidents not only endanger personnel but also lead to costly work stoppages. Prioritizing safety builds trust and reduces liability.

Long-Term Cost-Benefit of Upgrades

High-quality coatings may cost more upfront, but their extended lifespan and reduced maintenance needs often make them the most cost-effective option. Lifecycle cost analysis reveals how investing in better materials can save tens of thousands of dollars over time —not just in repairs, but in reduced downtime and labor.

From a sustainability perspective, longer intervals between recoatings mean fewer disruptions, less material waste, and lower energy consumption associated with repeated maintenance cycles. Rehabilitating with premium, environmentally responsible products adds measurable value to infrastructure assets while supporting long-term environmental stewardship. It’s a smarter investment for both budgets and the planet.

How to Extend the Service Life of Aging Water and Wastewater Assets

Long-term infrastructure planning is essential for maximizing return- of- investment (ROI) and maintaining uninterrupted water service. Tank rehabilitation should be woven into a larger strategy that includes asset tracking, condition monitoring and capital planning. Instead of operating in reactive mode, organizations can shift to a proactive model—saving money, improving safety and meeting public demand.

High-performance coatings play a pivotal role in this shift, offering durable protection that complements strategic asset management.

Build a Strategic Asset Management Plan

Successful asset management starts with a clear understanding of what you own, what condition it’s in and how it fits into your operational priorities. This process involves creating an inventory of tanks, assessing current conditions and assigning a risk rating to each asset. Plans should include inspection schedules, maintenance timelines and triggers for rehabilitation.

A strategic plan transforms reactive maintenance into predictive action. With this clarity, you can prioritize funding and minimize surprises.

Consider Rehabilitation Instead of Full Replacement

In many cases, tanks that appear outdated still possess structurally sound foundations.

Rather than defaulting to costly replacements, it makes more sense to rehabilitate what’s already there. Restoration is often quicker, less disruptive and significantly cheaper.

By layering on modern coatings, an old tank can meet or exceed the performance of a new one. This choice preserves historical investments while aligning with sustainability goals.

Perform Lifecycle Cost Analysis

Making informed decisions today can save resources for years to come.

When evaluating coatings or restoration methods, it's important to look beyond upfront pricing. Lifecycle cost analysis compares long-term costs—maintenance, reapplication intervals, labor and service disruptions—across multiple options. Often, premium coatings yield the lowest cost-per-year of service.

This data-driven approach supports smarter procurement and budgeting.

Future-Proof Through Detailed Documentation

Every rehabilitation project should include comprehensive documentation, from material batch numbers and thickness readings to contractor notes and inspection results. This record-keeping serves as a valuable reference during future maintenance or audits. It also helps confirm warranty eligibility and aids in troubleshooting if issues arise.

Organized documentation is the bridge between today’s work and tomorrow’s planning. Future-proofing your asset starts with knowing its history.

Protect Aging Water and Wastewater Infrastructure with Coatings and Linings from Sherwin-Williams

Rehabilitating aging water tanks is vital for long-term resilience, cost control and regulatory compliance. With a combination of preventative maintenance, strategic restoration and premium coatings, you can give aging tanks a new lease on life.

Sherwin-Williams is here to help you protect what matters most. Our experts will work with you to evaluate your tank’s condition, recommend tailored solutions and support your project from start to finish.

Whether you're planning a simple overcoat or a complete tank overhaul, we have the products and expertise to deliver. Contact us today to learn more.