Wastewater treatment plants (both municipal and industrial) face significant risks from aging infrastructure and corrosion-related failures. These risks carry heavy financial costs, regulatory penalties, and environmental consequences. Fortunately, protective coatings and linings can mitigate much of this damage. Below, we explore key statistics and insights in five areas and show how expert coating services (like those provided by Markley’s Precision) help prevent catastrophic failures.
1. Financial Impact of Corrosion and Failures
Corrosion Costs
Corrosion is a leading cause of wastewater infrastructure failure. NACE (now AMPP) reported to the U.S. Congress that corrosion in water and wastewater systems costs about $36 billion annually in direct expenses. This figure has likely grown with inflation and aging assets. Microbiologically induced corrosion (from sewer gases like H₂S forming sulfuric acid) alone causes “billions of dollars” in damage to U.S. water and sewer systems each year.
Unplanned Repairs & Downtime
When infrastructure suddenly fails (pipes burst, tanks leak, equipment breaks), utilities incur steep unplanned costs. Emergency shutdowns result in repair expenses, lost productivity, and service disruptions. One analysis noted that even 5 minutes of wastewater plant downtime can trigger costly responses – including:
- Spill cleanup
- Labor and materials for repairs
- System rebalancing upon restart
In 2019, drinking water outages and sewer backups from infrastructure failures cost American households $2 billion (e.g. property damage, service losses); by 2039 those annual costs could reach $14 billion if investments lag.
Deferred Maintenance vs. Replacement
Many wastewater facilities defer maintenance due to budget constraints, but this often leads to more expensive fixes later. The American Society of Civil Engineers (ASCE) found:
- An $81 billion gap between actual and needed water/wastewater capital investments in 2019
- A $10+ billion annual shortfall in operations & maintenance funding
Cutting maintenance may save money in the short term, but a “run to failure” approach often means costly emergency projects or full replacements. In contrast, every $1 spent on corrosion control can save about $8.50 in future repair and replacement costs. For example, refurbishing old concrete tanks with proper coatings can avoid an expensive rebuild – one case in Europe saved roughly €200,000 versus new construction by restoring and lining existing tanks.
2. Regulatory & Compliance Risks
Clean Water Act Violations
Failing wastewater infrastructure can lead to permit violations – such as releasing untreated or partially treated effluent into the environment. Regulatory agencies aggressively enforce the Clean Water Act. The U.S. EPA issued over $14 billion in water pollution penalties from 2011 to 2021.
Key facts about penalties:
- Fines can range from tens of thousands to millions of dollars depending on severity
- One city was fined $400,000 (after a prior fine) for ongoing wastewater treatment violations and was forced under a consent decree to invest $25 million in plant upgrades
- Federal law allows penalties up to $56,000 per day per violation (adjusted for inflation) in civil cases
- Even higher penalties for willful or criminal violations
Environmental Penalties
Beyond direct fines, utilities may be liable for environmental damage. Infrastructure failures often cause sanitary sewer overflows (SSOs) or unpermitted discharges that harm waterways. Raw sewage spills introduce:
- Pathogens
- Excess nutrients
- Toxins into rivers and streams
This leads to fish kills, algal blooms, beach closures, and threats to public health. Regulators can mandate costly remediation projects in addition to monetary fines. For example, after a major sewer overflow incident, a city might be ordered to fund stream restorations or habitat cleanups alongside paying penalties.
Common Compliance Issues
Some typical failures that trigger regulatory action include:
- Sewage Overflows: Aging pipes or plant breakdowns can cause raw sewage to overflow into streets or waterways. This happens up to 75,000 times per year in the U.S. when plants experience downtime or capacity exceedance. Every reportable spill, even minor, can result in fines and increased oversight.
- Equipment Malfunctions: If critical treatment units (pumps, clarifiers, aeration systems, etc.) fail due to corrosion or mechanical issues, the plant may violate effluent limits (e.g. exceeding ammonia or bacteria levels). Repeated exceedances often prompt enforcement.
- Structural Failures: Collapse of a tank or pipe can lead to massive discharges of untreated wastewater. Such events not only incur cleanup costs but can also bring lawsuits, consent decrees, and negative publicity for the operator.
Staying in compliance requires proactive maintenance to prevent these failures. Otherwise, utilities risk legal action, federal/state fines, and the public’s trust.
3. Industry Trends: Maintenance vs. Catastrophic Failures
Aging Infrastructure
The U.S. has nearly 15,000 wastewater treatment plants, many decades old. ASCE’s 2017 infrastructure report card gave U.S. wastewater a grade of “D+”, citing deteriorating systems and insufficient funding. Key statistics:
- Plants operate at 81% of design capacity on average
- About 15% of facilities are at or beyond their capacity limits
- This increases the risk of overflows and breakdowns
- In industrial facilities, wastewater systems often handle highly corrosive flows (chemicals, brines, etc.), which can wear out equipment faster if not properly protected
Deferred Maintenance
Tight municipal budgets and “out of sight, out of mind” mentality have led many operators to postpone upkeep. Preventative maintenance like re-coating tanks or replacing corroded parts is sometimes delayed until a failure occurs. This trend is dangerous – as preventable failures turn into emergency fixes that cost far more.
Surveys in the water industry emphasize shifting from reactive to proactive maintenance. For example, implementing predictive maintenance (regular inspections, corrosion monitoring, etc.) can catch early warning signs and avoid an emergency shutdown. Yet, many utilities still run critical assets to failure due to funding or staffing constraints.
Failure Frequency
Without adequate maintenance, catastrophic incidents are becoming more common. High-profile failures – like major plant breakdowns or sewage floods – have prompted state and federal interventions in some cases. Even routine issues like small pipe leaks can accumulate into significant service disruptions.
In 2019 alone:
- 300,000 water main breaks occurred in the U.S. (some portion in sewer systems)
- Wastewater systems frequently experienced leaks and blockages
The trend is clear: infrastructure that isn’t regularly maintained will fail, and those failures carry steep costs (financial and societal). Industry data shows every dollar not spent on maintenance now will require multiple dollars later to address the resulting failure.
4. Protective Coatings & Linings as Preventative Measures
Investing in high-performance protective coatings and linings for wastewater infrastructure is one of the most effective strategies to combat corrosion and extend asset life. Markley’s Precision specializes in exactly this: applying industrial-grade coatings (like epoxies, polyureas, polyurethanes, and advanced hybrids) to wastewater equipment and structures.
How Coatings Prevent Damage
Protective linings create a barrier between corrosive wastewater and the structural substrate (concrete or metal). In wastewater environments, hydrogen sulfide from sewage can convert to sulfuric acid, which eats away unprotected concrete and steel. Coatings prevent that chemical attack by isolating the surface. They also:
- Block moisture ingress
- Resist abrasion from grit and sludge
Examples of coating types:
- Epoxy coatings are highly acid-resistant and form a tough, waterproof seal on concrete – ideal for wet wells, clarifier tanks, and pipes
- Polyurethane and polyurea coatings offer flexibility (useful for structures that expand/contract or vibrate) and fast cure times for quick return to service
- Many modern linings are even ANSI/NSF 61 certified, meaning they’re safe for potable water contact, reflecting their chemically inert nature
Extending Asset Lifespan
When properly chosen and applied, coatings can dramatically lengthen the service life of infrastructure. Asset owners report that regularly re-coating equipment can add decades of life, avoiding premature replacements. One manufacturer notes their epoxy linings provide “a significant extension of plant and equipment service life”, keeping wastewater treatment efficiency high.
In practical terms:
- A concrete tank that might start crumbling after 5–10 years in corrosive service can instead last 20+ years with a robust lining and maintenance program
- Coatings also improve performance: a smooth, lined pipe or channel has higher flow efficiency and is easier to clean, which further helps the facility run optimally
Importance of Quality Application
To realize these benefits, the coatings must be applied correctly. Even the best coating can fail if installation is poor. Surface preparation is critical – all grease, corrosion, and debris must be removed (often by sandblasting) before coating.
Key application factors:
- Application thickness must be controlled per manufacturer specs
- Curing time must be properly observed
- Environmental conditions must be tightly controlled
- If done improperly, defects like pinholes or improper cure can let corrosion begin underneath
That’s why experienced contractors like Markley’s Precision are invaluable; they ensure the lining is “flawless with no blisters, pores or pinholes” so the substrate stays fully protected. In short, high-performance coatings form the frontline defense against wastewater’s destructive effects, preventing sudden failures and reducing long-term maintenance costs.
5. Case Studies & Examples
Real-world examples illustrate how proper (or improper) coatings impact wastewater infrastructure outcomes:
Catastrophic Failure from Poor Coating
A case study at a wastewater plant in Poland showed what can go wrong with subpar linings. An epoxy coating that was not up to standard failed within just 2 years, leading to severe concrete corrosion in the tanks. The premature coating failure exposed the concrete to acidic attack, illustrating that using the wrong product (or poor application) can accelerate infrastructure damage rather than prevent it.
Longevity with High-Quality Lining
In contrast, a municipal plant that installed a premium epoxy lining in a clarifier basin reported no coating flaws or failures even after 11+ years of continuous operation. The durable lining prevented corrosion and wear on the underlying concrete and steel, allowing the clarifier to function like new for over a decade. This example demonstrates the lifespan extension achievable with quality materials and installation.
Cost Savings via Rehabilitation
Rather than waiting for a corroded structure to collapse, some facilities choose to rehabilitate. In one project, an aeration tank from the 1970s was restored and coated instead of being demolished and replaced. The proactive refurbishment saved the operator about €200,000 compared to building a brand-new tank. It also minimized downtime. This underscores that preventive maintenance (like re-coating) is often far more economical than reacting to a failure.
These cases reinforce the value of protective coatings: when done correctly, they prevent failures, avoid expensive rebuilds, and keep plants running safely. When neglected or done poorly, the consequences can be costly and abrupt.
Conclusion: Mitigating Risks with Expert Coating Services
The risks of wastewater infrastructure failure are too large to ignore – from multi-million-dollar corrosion costs and regulatory fines to environmental damage and service disruptions. Industry trends show that aging plants will face more frequent failures if we don’t invest in maintenance. Protective coatings and linings are a proven, cost-effective solution to bolster these critical assets against corrosion and wear. By utilizing high-performance coatings (epoxy, polyurea, polyurethane, etc.) and skilled applicators, wastewater facility owners can significantly reduce the chance of catastrophic failures.
Markley’s Precision contributes to this proactive defense by bringing expertise in wastewater painting and linings. Their services help municipalities and industries extend the life of treatment tanks, pipes, and equipment – ultimately saving money and ensuring compliance. With proper coatings in place, wastewater plants can operate reliably, avoiding unplanned shutdowns and mitigating the financial and regulatory risks that come with infrastructure failure. In summary, investing in protective linings today is a smart strategy to keep U.S. wastewater systems safe, efficient, and regulation-compliant for years to come.