Why Aging Infrastructure is a Silent but Growing Risk

We often think of infrastructure as something permanent – bridges, buildings, pipelines, processing plants – all solid, all safe… right?

But the reality is, much of the infrastructure we rely on every day is ageing. Some of it was built 30, 40, even 60 years ago! While it might still be standing, what lies beneath the surface could be hiding serious risks to your business, your people, and your community.

Let’s unpack why aging infrastructure is a silent but growing risk and the associated risks – from structural integrity to process safety and WHS – and why climate change may be adding fuel to the fire.

The Hidden Risks of Aged Infrastructure

1. Structural Integrity Risks

Structures degrade over time. Concrete can crack, steel can corrode, timber can rot. These aren’t just maintenance issues – they’re critical risk issues.

Think about:

• Bridges and platforms exposed to water, salt, or chemicals

• Load-bearing structures weakened by corrosion

• Foundations shifting due to soil movement

The problem? Degradation isn’t always visible – and failure doesn’t happen gradually. It often happens suddenly, and catastrophically.

And it's not just wear and tear. Many structures were designed decades ago under completely different assumptions. Take multi-level carparks, for example — they were built for lighter mechanical vehicles, not the heavier electric vehicles we see today, or original roof designs may not account for modern loads such as solar panels.

Many structures are now being used in ways they weren’t originally designed for. Are we regularly reassessing those design assumptions as operations evolve?

2. Process Safety Risks

Ageing infrastructure often includes legacy plant, equipment, and piping systems. Without proper inspection, maintenance, and upgrade programs, you’re at risk of:

• Leaks and spills due to pipe corrosion

• Pressure vessel failures

• Control system malfunctions due to outdated tech

Organisations may focus on day-to-day operations, but legacy systems can fall through the cracks. If a failure affects high-risk chemicals, gases, or processes – the consequences can be deadly.

3. WHS and Public Safety Risks

When infrastructure fails, it’s often frontline workers and the public who bear the brunt. Slip, trip, and fall hazards increase around poorly maintained walkways, ladders, and platforms. Electrical systems without modern protection mechanisms can spark fires or electrocution. And when buildings deteriorate, mould, asbestos, and air quality issues become real health risks.

Is Climate Change Making It Worse?

It’s an interesting question, isn’t it?

When we think about ageing infrastructure, we often picture concrete, steel, and timber. But what happens when those materials — and the systems built around them — start facing conditions they were never designed for?

We’re seeing shifts in climate patterns around the world, and it raises some valid questions for any business relying on older assets or infrastructure.

• Can older stormwater systems really cope with today’s rainfall volumes — especially when major rain events are becoming more intense and more frequent? Blocked drains, overwhelmed detention basins, and water ingress can cause widespread structural damage and serious health risks.

• What happens to our cooling systems during prolonged heatwaves? Are they capable of running efficiently, or do they begin to falter — placing critical equipment, processes, or even indoor workers at risk?

• Do extreme temperatures change the way materials behave over time? We know heat can expand and stress concrete and metal, but what about electrical systems, seals, and components not designed for these extremes?

• How well are our older buildings holding up against cyclonic winds and violent storms? Were they built to withstand the conditions we’re now starting to see more regularly — or are we trusting systems that are no longer fit for purpose?

• And what about the people working outdoors? Do rising temperatures change the way we schedule work? Will we still expect people to work outside in prolonged, extreme temperature conditions — or is it time to rethink what’s reasonable, and what’s safe?

These aren’t just thought experiments — they’re real-world questions that need answers. Because sometimes, the most critical risk isn’t just the infrastructure itself — it’s how the world around it is changing.

What Happens When the Knowledge Retires?

Here’s something we don’t talk about enough: the infrastructure might still be standing — but the people who built it, maintained it, and understood its quirks are leaving the workforce in droves.

The retirement of the Baby Boomer generation is more than just a workforce shift. It’s a massive loss of embedded knowledge — the kind that was never written down. They knew the history of your assets. They remembered why that patch of concrete was repaired differently, which valve had a known delay, or why a manual workaround was introduced 15 years ago that never made it into the procedures.

We’re not just losing skillsets — we’re losing context. And in risk management, context is everything.

Without that context, we risk:

• Misunderstanding the current condition or limitations of infrastructure

• Repeating past mistakes that were quietly corrected without documentation

• Over-relying on systems or assumptions that are no longer valid

• Missing the subtle signs of degradation that only experienced eyes can spot

Are we capturing this knowledge before it walks out the door? Or are we assuming our systems and drawings are telling us everything we need to know?

Now combine this with ageing infrastructure and a changing climate, and the gap becomes even wider. It’s not just about physical deterioration — it’s about organisational memory loss.

Do You Know the Condition of Your Assets?

Some organisations don’t have a current, complete picture of their ageing infrastructure – or a clear risk-based plan to address it. That’s where things start to get dangerous. Without proper assessments, we’re making assumptions about safety that might no longer be true.

This isn’t about being alarmist – it’s about being prepared.

Before You Assume “It’s Always Been Fine”...

Ask yourself:

• Do you know the installation, modification and maintenance history?

• When was the last structural integrity inspection?

• Are our process safety risks increasing with asset age?

• Have we considered the impact of extreme weather events on our critical infrastructure?

• Do we have a risk-based asset management plan in place, and do they include replacement strategies?

Why Aging Infrastructure is a Silent but Growing Risk