Posted on October 10, 2025 by Brent Phillips

Water towers, a vital infrastructure asset for communities, have long-term reliability needs that depend on the health of protective coatings. For water asset managers and city water authorities, knowing how to detect early signs of coating failure can prevent costly repairs, protect water quality, and keep service uninterrupted. That can highlight five essential points to help you spot problems early and apply preventive maintenance practices to your water towers.

1. Visible Warning Signs of Coating Failure

The first step to detecting early signs of coating failure is identifying changes in appearance. Common visible symptoms on water towers include:

• Discoloration (brown or red streaks)
• Blistering or peeling paint
• Rust formation at seams or edges
• Cracks, pinholes, or surface pitting
• Blue-green stains in copper components

Regularly touring around the external and internal tanks can help reveal signs of coating failures. Take note of any new visual changes and investigate immediately.

2. Common Causes Protective Coatings Fail

Understanding what leads to coating failure helps you detect early signs with context:

• Moisture exposure and humidity speed up corrosion, especially in harsh climates
• Improper surface preparation before coating can cause early adhesion loss
• Mechanical damage from equipment or weather
• Chemical contamination in water or cleaning agents
• Aging coatings past their service life

3. Inspection Best Practices for Detecting Coating Failures

Routine water tank and tower inspections are key to preventive maintenance. Methods that help you detect early signs include:

• Holiday testing, or discontinuity testing to find pinholes and thin spots in protective coatings
• Wet sponge (low voltage) and spark (high voltage) testing
• Adhesion tests for epoxy, as loss of adhesion signals coating failure
• Visual and tactile checks for roughness, chalking, or flaking

Inspection Checklist:

• Examine tank coating for stains, rust streaks, or cracks
• Inspect bracing, supports, and fittings for corrosion or loose connections
• Check for leaks or water seepage
• Record inspection results for future comparison

4. Preventive Maintenance on Protective Coatings

Effective preventive maintenance can address issues before they get worse and help water asset managers detect early signs by routinely:

• Scheduling routine inspections
• Repair surface cracks or changes as soon as they are detected
• Remove rust and reapply protective coatings to affected areas
• Train staff on inspection techniques
• Maintain spare hardware and touch-up materials for fast repairs

5. Long-Term Benefits of Early Coating Failure Detection

City water managers and water asset managers who consistently detect early signs of coating failure gain significant, lasting benefits:

• Reduced repair costs and downtime
• Protected water quality and safety
• Extended service life of water towers
• Strengthened infrastructure investment

A proactive approach plus hands-on vigilance can prevent expensive surprises by keeping your community’s water system strong, safe, and reliable. By learning how to detect early signs and establishing preventive maintenance routines, water towers can serve for decades without significant interruptions.

For water asset managers and city water authorities committed to safeguarding water towers, consider partnering with Cunningham Sandblasting for your next inspection or maintenance project. Their water tank and tower inspectors and experienced professionals deliver reliable sandblasting, painting, and structural care services tailored to your facility’s needs. If you’re ready to schedule an assessment or want more information on preventive maintenance for water towers, call Cunningham Sandblasting at 620-848-3030 today and make proactive care a priority for your community’s most visible asset.