Cooling tower failures caused by poor maintenance can include:

Corrosion: Cooling towers are often made of metal and can corrode over time due to exposure to water, chemicals, and other environmental factors. Poor maintenance can accelerate the corrosion process, structural damage, and leaks of chemicals from your cooling tower onto roofs, into rivers and the ground.

Scale buildup: Minerals and other impurities in the water supply can build up in the cooling tower and reduce its efficiency. Without regular cleaning and maintenance, scale buildup can cause blockages and damage to the tower’s components.

Clogging: Cooling towers rely on a system of pipes, nozzles, and filters to distribute water and air. Clogging can occur when debris, sediment, or algae accumulate in these components, reducing the flow of water and air and impairing the tower’s cooling capacity.

Faulty drift eliminators:  Faulty drift eliminator material, damaged components, and poor installation allow bacteria such as Legionella or hazardous chemicals to become airborne. Once airborne the bacteria and chemicals contact people, damage steel such as roofs, vehicles, and buildings and stain glass windows.  

Fan malfunction: Cooling tower fans are responsible for drawing in air and expelling heat. Over time, fans can become damaged, misaligned, or clogged with debris. If not addressed, fan malfunction can lead to reduced cooling efficiency and increased energy consumption. Fans that fail at high speed can smash into the casing and supports. Components could also fly off to kill or injure nearby workers.

Noisy motors, pumps, and distribution systems:  Poorly maintained cooling tower motors, pumps, and water distribution systems are not only inefficient and unsafe, but also noisy, squealing, and annoying to people that live or work close to a cooling tower. Poor maintenance is noise pollution.    

Water quality issues: Cooling towers rely on a steady supply of clean, fresh water to function properly. Poor water quality due to inadequate treatment or filtration can lead to microbial growth, corrosion, and other problems that can compromise the tower’s integrity and performance.

Electrical problems: Many cooling towers rely on complex electrical systems to operate their pumps, fans, and controls. Poor maintenance can lead to electrical failures, which can cause the tower to shut down, overheat, or malfunction in other ways.

Structural damage: Cooling towers are often exposed to harsh weather conditions, including wind, rain, and extreme temperatures. Poor maintenance can leave them vulnerable to structural damage, including the collapse of its fill packs or hot water decks due to corroded bolts and failed supports.


Do you need cooling tower parts, service, or inspections? Are you considering refurbishing your cooling system or replacing it all together – or maybe you just want to talk to someone about advancements in cooling technology, system efficiency and current industry standards?

If so, give us a call at 908-541-1010 or click on the (contact us) link at the bottom of the page. Our sales engineers are ready to answer your questions and discuss your needs.