Water storage tanks are a critical part of many buildings. Whether they supply drinking water, feed a boosted system, support cooling processes, or store water for welfare facilities, they play a major role in keeping a business running smoothly. When a tank begins to age or deteriorate, it can lead to hygiene risks, compliance issues, increased energy costs, and in the worst cases, operational downtime.

The challenge is that most commercial tanks sit quietly in plant rooms, service risers, or rooftop enclosures, so problems are often missed until they become serious. With that in mind, here are the early warning signs that your commercial water tank may be due for replacement.

Visible Damage to the Tank

A simple inspection can reveal a lot about the health of a water tank. Signs of physical deterioration should never be ignored. Make sure to get in touch with us if you witness any of the signs below.

Corrosion

Older galvanised steel tanks are especially prone to rust. Once corrosion starts, the metal becomes weaker and more brittle. Rust can also contaminate the stored water, which may cause complaints from staff or tenants and breach water hygiene standards.

Look out for:

• Flaking metal
• Brown patches
• Soft or weakened surfaces
• Signs of moisture coming through the tank body

Corrosion is progressive, which means it only gets worse with time. Replacement is usually the best solution once rust is visible.

Cracks and Bulging

Plastic and GRP tanks do not rust, but they can crack or warp. Cracking often results from heat fluctuations, UV exposure, or structural stress. Bulging walls or distorted panels can indicate internal pressure issues or weakened tank integrity. In a commercial setting, these faults can quickly lead to leaks and significant property damage.

Declining Water Quality

Water quality complaints are one of the clearest signs of a failing tank. In a business environment, this can lead to compliance failures or unusable welfare facilities.

Common warning signs include:

• Brown or yellow water
• Cloudy or gritty water
• Metallic or stale smells
• Sediment coming through taps or outlets

These symptoms often occur when internal tank surfaces are breaking down. Bacterial growth can also develop if the tank no longer seals correctly or if the internal surfaces have begun to degrade. Any change in water quality should be taken seriously, especially in buildings that must follow strict water hygiene requirements.

Echo Square ensures that all of the water tanks we install follow stringent Legionella control regimes that are compliant with the Health & Safety Executive’s Approve Code of Practice (ACOP L8).

Leaks or Damp Patches Around the Tank

A leaking water tank can cause major issues in commercial environments. A slow drip can develop into structural damage, plant room flooding, or disruption to business operations.

Watch for:

• Pooling water around the base of the tank
• Damp patches on nearby walls or ceilings
• Corrosion around joints and pipework
• Overflow pipes running constantly

Leaks often indicate structural weakness or failing connections. In many cases, a leaking tank is already at the end of its serviceable life.

High Humidity in Plant Rooms

If your plant room or tank area feels unusually warm or humid, the tank may not be sealing or insulating as it should. Moisture escaping from an ageing tank can affect electrical components, damage surrounding equipment, and increase the risk of mould growth.

Commercial tanks should be well insulated, fully sealed, and properly ventilated. If the atmosphere around the tank has changed noticeably, it is worth arranging an inspection.

Reduced Water Pressure or Flow Problem

Commercial buildings often rely on strong, consistent water pressure to keep facilities running properly. Low flow rates can disrupt kitchens, showers, toilets, production processes, or boosted cold water systems.

Pressure issues can occur when:

• Sediment builds up inside the tank
• Valves fail due to age
• Internal pipework becomes obstructed
• The tank is no longer filling or distributing water efficiently

Modern replacement tanks often include improved internal fittings that help restore and maintain reliable pressure.

Excessive Sediment or Limescale

Over time, commercial water tanks can accumulate large amounts of sediment, especially in hard water areas or where maintenance has been inconsistent. Limescale buildup can damage fixtures and reduce system efficiency.

If you notice:

• Heavy sediment layers
• Grit or particles in strainers
• Scale deposits around outlets or pumps

…it may be a sign that the inside of the tank has deteriorated. While cleaning can help, excessive buildup usually means the tank is reaching the end of its lifespan.

Unusual Noises or Malfunctioning Valves

Noises such as gurgling, clicking, or constant filling can indicate mechanical issues associated with an ageing tank. A failing or sticking ball valve can lead to overflowing, wasted water, or inconsistent levels inside the tank.

If repairs have been made multiple times, it often means the tank configuration is no longer reliable. Replacing the tank is usually a more cost effective long term solution.

Non Compliance With Current Regulations

Commercial buildings must follow strict water hygiene standards, including ACOP L8, HSG274, and relevant building regulations. Many older tanks do not meet modern requirements and may lack:

• Correctly screened vents
• Insulated lids
• Suitable internal coatings
• Proper structural support
• Approved materials for potable water

If a tank does not meet current standards, replacement is often the only way to ensure compliance and reduce legionella risk.

Repeated Repairs or Increased Maintenance Costs

If the tank requires frequent call outs, the real problem may be age rather than individual component failures. Repeated repairs can quickly exceed the cost of simply installing a new tank.

A new commercial tank typically offers:

• Better thermal efficiency
• Safer water storage
• Compliance with modern standards
• Longer life expectancy
• Reduced maintenance requirements

For most businesses, a planned replacement is far less disruptive than an emergency one.

Final Thoughts

A healthy water tank is essential for the smooth operation of any commercial building. Early warning signs such as leaks, poor water quality, corrosion, low pressure, or regulatory failures should never be ignored. Replacing a tank before it fails completely can prevent serious damage, reduce costs, and protect the health and safety of building users.