Deciding whether to rehabilitate or replace a lift station is one of the most important infrastructure decisions a utility can face. The choice involves balancing conditions, cost, performance, and long-term reliability. Without a structured evaluation process, utilities risk overinvesting in repairs or prematurely replacing assets that still have useful life remaining.

At HR Green, we guide municipalities through a proven, repeatable assessment process that helps leaders make confident, data-driven decisions. A thorough condition assessment lays the groundwork for a well-informed rehabilitation or replacement strategy. Understanding and weighing key criteria, such as system age, performance data, and future capacity needs, helps determine the most effective path forward for your community.

Conducting a Lift Station Condition Assessment

A comprehensive condition assessment is the cornerstone of effective asset management. It provides the facts needed to prioritize investments and plan for the future. When HR Green’s engineers evaluate a lift station, we examine six core categories: structural, mechanical, electrical, HVAC, operational, and safety.

Structural Assessment

Structural assessment involves evaluating the wet well’s integrity, coatings, and structural layout. We look for cracks, corrosion, water intrusion, and deterioration in concrete or linings. If the structure is still sound, it may be a strong candidate for rehabilitation.

Mechanical Assessment

Mechanical systems are the heart of a lift station. We assess pump performance, vibration, clogging frequency, and overall efficiency under load. Pump drawdown testing helps determine if current equipment meets design standards or if replacement is necessary.

Electrical Assessment

Electrical systems often dictate whether a lift station can be safely and efficiently operated. We review motor control centers (MCCs), control panels, surge protection, arc-flash labeling, and backup power systems. Compliance with modern safety standards is essential because outdated or unsafe panels often make replacement more practical.

HVAC and Environmental Controls

Many older stations have failing ventilation or heating systems. Poor HVAC performance accelerates corrosion and shortens electrical equipment life. Proper climate control promotes worker safety, extends asset life, and supports compliance with NFPA 820 standards.

Site Access and Operational Considerations

We also assess whether the site supports safe and efficient maintenance. Can crews easily reach the station year-round? Is there space for a crane truck or bypass pumping system? These logistical factors can determine whether rehabilitation is feasible.

Rehabilitate vs. Replace: How to Decide

After assessment, each factor is scored and analyzed to create a defensible decision matrix. This framework compares life-cycle costs, schedule impacts, and risk exposure. The key criteria below help guide the decision.

1. Structural Integrity

If the existing structure is in good shape, rehabilitation is often the most cost-effective path. However, if the wet well concrete is severely deteriorated or the site cannot accommodate new equipment, full replacement is typically the better option.

2. Age and Condition of Equipment

When pumps, valves, and electrical systems have exceeded their life expectancy or are no longer supported by manufacturers, replacement may offer more long-term value. However, if these components can be selectively upgraded, rehabilitation can deliver strong results at lower cost.

3. Physical and Schedule Constraints

Tight sites and limited construction windows can influence the decision. Rehabilitation allows for staged upgrades with minimal downtime, while full replacement may require longer bypass pumping and permitting. The Hydraulics Institute Standards provide key dimensional guidelines for evaluating whether an existing wet well can support modern performance requirements.

4. Capacity and Future Growth

Population growth, aging infrastructure, and rising infiltration and inflow all drive the need for additional pumping capacity. If projected flows will soon exceed the current station’s capabilities, replacement for higher capacity is often more prudent than incremental rehabilitation.

5. Regulatory and Code Compliance

Older stations often struggle to meet updated regulations such as NFPA 820, redundancy requirements, or modern backup power standards. If compliance upgrades cannot fit within the existing footprint, replacement becomes the more practical solution.

6. Life-Cycle Cost and Risk

Utilities must weigh total cost of ownership, including maintenance, energy, and risk of failure. In some cases, a phased rehabilitation is economical and minimally disruptive. In others, constructing a new lift station adjacent to the existing one and decommissioning the old may be more cost-effective over time.

Building a Framework for Confident Decisions

Choosing between rehabilitation and replacement is not just an engineering judgment, it is a strategic investment decision that affects reliability, safety, and budget efficiency for years to come. By using a structured condition assessment and life-cycle cost analysis, communities can make informed, defensible decisions that extend asset life and optimize resources.

At HR Green, our municipal and wastewater engineering professionals partner with utilities across the country to deliver clear assessments, sound recommendations, and practical design solutions. Whether you are planning a small rehabilitation or a complete lift station replacement, our team can help you analyze risks, minimize downtime, and build infrastructure that serves your community for decades to come. Contact us today to learn more!