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Water towers are one of the most important pieces of infrastructure for municipalities, manufacturing facilities, distribution warehouses, and many other industrial or commercial locations around the nation. These structures store water for many different purposes such as supplying water for important industrial processes and fire protection systems, drinking water, or thermal storage.

Water towers rely on specialized coatings on the interior and exterior to help protect the steel from the harsh surrounding environment or the content of the tank from deteriorating over time. By identifying the top signs of coating failure on water towers as they arise, you can address these issues as soon as possible and prevent them from escalating into expensive emergencies that can threaten water quality or lead to corrosion resulting in expensive repair bills.

Visible Rust Formation on Steel Surfaces

One of the most visible signs of coating failure is the buildup of rust. You’ll notice a reddish-brown discoloration when moisture breaks through the barrier and reaches the underlying steel substrate that makes up the tower. Rust usually starts forming with small streaks that expand if no one treats them. The most common starting points are around bolt connections, welded joints, or other areas with sharp edges.

It’s important to perform regular inspections of visible surfaces of the tower, including tank walls, support legs, and connecting hardware for any signs of rust development. Finding and taking care of rust early can help prevent it from spreading to larger areas of the structure and causing more damage.

Chalking and Fading of the Exterior Coating

Chalking occurs when the coating’s binder system breaks down under ultraviolet radiation, leaving behind loose pigment particles on the surface. You can usually identify chalking by running your hand along the exterior surface of the tank. If it leaves behind a white or colored residual powder, it’s likely experiencing chalking. This is a type of degradation that compromises the coating’s protective capabilities and usually requires cleaning, followed by a recoating evaluation.

If you don’t catch or take care of chalking, it can lead to fading, which drastically causes the coating to lose its color intensity and vibrancy. The original paint color will wash out and appear noticeably lighter than when it was first applied. While some fading through UV exposure is natural, rapid visual changes may indicate that the coating isn’t protecting as well as it should, leaving the underlying steel far more vulnerable to corrosion and other types of environmental damage.

Peeling and Flaking Paint Layers

As the adhesion between the coating layers fails or wears down, the paint may start to crack, peel, or chip away from the substrate. You may notice curled edges, loose flakes, or entire sections of coating that can be easily removed by hand. It’s important to document the location and extent of these peeling areas during routine inspections.

Flaking represents a more advanced stage of coating failure where small pieces of paint actively fall away from the surface. These loose particles can contaminate the surrounding area and expose the underlying steel to direct environmental exposure. If you notice large amounts of paint flakes around the base of the water tower, it could be a sign of widespread coating deterioration that requires immediate attention.

Cracking and Splitting in the Coating System

Another sign of coating failure on water towers is when you notice a long crack developing in the protective layer. These cracks occur when the film becomes brittle and loses its ability to flex around the curvature of the underling substrate. Many outside conditions can cause these cracks, including temperature fluctuations, structural movement, and the age of the protective coating. These linear breaks in the coating system create pathways for moisture infiltration and subsequent corrosion development.

If the cracks get wide enough to cut completely through the coating and expose the steel substrate beneath, that’s known as a split, and it’s a particularly dangerous sign of failure that requires immediate attention. Inspectors should pay attention to areas around structural joints, welds, and connection points where stress concentrations commonly cause coating splits. These openings require immediate repair to prevent rapid corrosion progression.

Blistering and Bubbling on Painted Surfaces

Blistering appears as raised, bubble-like formations on the coating surface caused by trapped moisture, solvents, or gases beneath the paint film. Blisters occur due to poor adhesion between the coating layers or contamination during the application process. Blistering areas require immediate inspection as they often occur before more serious coating failures that require intervention.

Bubbling occurs when blisters expand and multiply across larger surface areas. This widespread formation suggests systemic coating problems that may require complete removal and reapplication of the protective system. The presence of bubbling typically indicates moisture infiltration or chemical contamination that compromises the coating’s protective integrity.

Corrosion Around Bolts and Connections

When rust forms around connector areas such as bolts and hardware attachments, these areas create natural weak points in coating systems and usually require more careful inspection. While rust is common, other corrosion issues may include mineral deposits that spread out from these connection points. Inspectors should carefully examine all bolted connections, including those on ladders, platforms, and any other type of structural support.

The crevices and gaps around bolts trap moisture and contaminants, accelerating corrosion even when the surrounding coating appears intact. This localized corrosion can compromise structural connections and spread to adjacent areas if not addressed promptly. Regular inspection and maintenance of these critical connection points help prevent widespread coating failure.

Biological Growth and Contamination

Some of the most common and troublesome coating issues are the ones that occur naturally in the water tower’s environment. Biological growth appears as green, black, or brown patches of algae, mold, or mildew that adhere to the coating surface. Teams that notice these formations should address the biological contamination and remove it as soon as possible.

Other forms of biological contaminants may include bird droppings, pollen, or atmospheric deposits that can all cause the coating to break down. These contaminants create acidic conditions that attack the protective coating system and promote corrosion development. You can reduce the risk of biological damage with regular cleaning and removing these contaminants before they lead to further damage.

Contact Pittsburg Tank & Tower Group today to learn more about our water tower and tank maintenance services. Our team of experts is ready to assist you with preserving your assets, extending service life, and ensuring optimal performance. Reach out now to schedule an inspection or consultation and experience the quality and reliability that our services provide.