Predictive maintenance over preventive: How IoT is transforming system performance

Digital transformation is accelerating, and water systems are very quickly becoming the next frontier across the plumbing and mechanical sector.

For decades, plumbing infrastructure has operated largely out of sight; relying on manual inspections to catch leaks, corrosion, pressure instability and other hidden failures. But, as buildings grow increasingly more complex, infrastructure ages and water becomes more expensive to manage, facility teams are quickly finding that traditional maintenance approaches are simply not enough.

The scale of the challenge is sizable. According to a 2024 Department of Energy / EPA–cited study, average system water loss in U.S. distribution systems is around 16%, much of which is due to leaks, undetected failures and aging pipes. The American Society of Civil Engineers’ 2025 Report Card similarly warns that a significant portion of U.S. water infrastructure is at least aging, leaving many systems vulnerable to breaks, blockages and costly service interruptions. The financial impact is equally striking: federal energy and maintenance data show that reactive repairs can cost more than preventive or predictive maintenance, particularly in commercial and industrial facilities.

Meanwhile, the broader technological landscape is shifting rapidly. The International Energy Agency reports that the world is on track to surpass tens of billions of IoT-connected devices by 2030, with water infrastructure emerging as one of the fastest-growing categories for sensor deployment. These connected systems are beginning to redefine how plumbing performance is monitored, measured and optimized; from high-rise buildings and industrial plants to municipal networks and data centers.

Together, these pressures are pushing plumbing professionals toward a more proactive, data-driven approach. IoT-enabled sensors, cloud-connected monitoring platforms and AI-powered analytics now offer real-time visibility into flow rates, pressure dynamics, water quality, pump performance and even corrosion trends inside pipes. This intelligence allows contractors, engineers and building owners to detect anomalies before they escalate: transforming maintenance from a reactive exercise into a predictive strategy rooted in measurable risk reduction.

As the industry shifts toward smarter, connected infrastructure, plumbing systems are becoming intelligent, responsive assets: capable of diagnosing their own health, conserving water more effectively and supporting more resilient building operations. The result is an era in which data, not guesswork, drives performance.

IoT in action

Water management is entering a new era. Aging infrastructure, rising operational costs and mounting regulatory pressures are driving operators to rethink traditional monitoring approaches. From corrosion creeping through decades-old piping to subtle pressure fluctuations that signal early leaks, facilities can no longer rely on periodic manual checks alone.

Thankfully, the answer is here. Gartner and McKinsey research indicates that service-based IoT solutions improve infrastructure ROI by integrating monitoring, maintenance and reporting into a single predictable cost model; modern IoT systems are turning water safety into a continuous process.

By combining real-time sensors with advanced analytics, operators can gain the visibility needed to detect stagnation, backflow risks or chemical drift before these issues escalate. At the same time, smart data allows teams to optimize pump schedules, chemical dosing and flushing routines; reducing both water and energy consumption while minimizing operational labor.

Environmental and regulatory expectations are also reshaping the field. Standards such as LEED v4.1, the WELL Building Standard and ASHRAE 191 encourage real-time water quality measurement and leak mitigation. Investors and corporate tenants increasingly expect transparent reporting and proactive risk management, making continuous monitoring a core component of modern facility operations.

So, how does IoT play a role in improving water safety in large buildings? “IoT transforms water safety from a periodic check (using occasional grab samples and delayed lab reports) into a continuous process,” Director of Data Science and AI strategy at KETOS, Ganesh Hegde told me. “By deploying connected sensors and automated analyzers [like KETOS’ SHIELD platform], operators gain a real-time view of water movement and quality.” This, in turn, allows teams to detect signs of contamination or treatment drift early; before they ever become a problem. It also allows them to spot issues like stagnation, backflow risks or inadequate disinfectant residuals, and identify data patterns that can highlight infrastructure risks and even guide the necessary operational changes.

IoT has a plethora of capabilities to evolve passive infrastructure into active, data-driven networks, including:

• Pressure and leak sensors: modern flow and pressure sensors use ultrasonic, acoustic and differential pressure technologies to monitor water movement. They can detect microleaks before they escalate into catastrophic failures, identify sudden pressure spikes that might indicate valve or pump malfunctions and track stagnation zones that can increase microbial risks.
  • According to Hegde, “Flow, pressure and temperature are fundamental. Shifts in these indicators can reveal leaks, valve issues or pump failures before they become critical. Patterns over time are often the most valuable insights.”
  • More than safety, this real-time data helps facilities optimize water usage and energy consumption. It can monitor draw patterns in large facilities (like campuses) and adjust pump schedules to detect abnormal consumptions. This can, in turn, translate into cost-savings and improved sustainability metrics.
• Corrosion and pipe health monitoring: Corrosion remains a huge hidden risk in aging infrastructure. In-pipe corrosion coupons, electrochemical sensors and wall-thickness monitoring devices can now allow operators to quantify degradation over time. When paired with predictive algorithms, these sensors can forecast failure windows, enabling facility teams to plan maintenance or even replace parts of a system before leaks, burst or contamination occurs.
  • “Continuous water quality monitoring is fundamentally connected to predictive maintenance because water chemistry dictates the lifespan and failure points of a plumbing system,” Hegde explains. “Real-time knowledge of aggressive or protective water chemistry allows operators to anticipate failures and optimize treatment.”
• Water quality analytics: Beyond physical monitoring, water quality analytics provide an equally important view of system health. Sensors can measure parameters such as pH, turbidity, conductivity, chlorine levels, total dissolved solids and trace metals. This date can reveal subtle chemical changes that signal corrosion, scaling, disinfectant drift or contamination risks.
  • KETOS features a platform in this space. Its SHIELD system integrates high-frequency, lab-level sensing across multiple water parameters, offering continuous insight rather than intermittent sampling. “IoT devices act as the nervous system, generating real-time flow, pressure, and quality readings, while smart data is the brain translating these signals into actionable insights,” says Meena Sankaran, CEO and founder of KETOS.
• Digital twins and cloud dashboards: One of the latest and most exciting advances in smart plumbing include virtual modeling and cloud-based analytics. Digital twins can create a “virtual replica” of a building’s plumbing system. This allows engineers to simulate water flow, load scenarios and emergency responses without risking real-world damage.
  • “Continuous water data keeps the virtual model aligned with real-world conditions,” Hegde notes. “The goal is to make water data a first-class citizen in the broader operating system.” Predictive models can pinpoint high-risk zones, recommend maintenance actions, and even automate interventions like flushing cycles or chemical adjustments before problems appear onsite.
  • Cloud dashboards can aggregate sensor data from across a campus or facility, presenting operators with actionable insights in an intuitive visual format. Predictive models can leverage this information to pinpoint high-risk zones, recommend maintenance actions and even automate interventions.

Working together, these technologies perfectly demonstrate what smarter plumbing looks like: a connected ecosystem where flow, pressure, pipe health and water quality are continuously monitored and optimized. The result? Safer water, lower operational costs, extended system life and compliance with increasingly stringent regulatory and sustainability standards.

How AI and predictive maintenance are changing operations

Traditional preventive maintenance schedules — weekly flushes, periodic sampling, and routine inspections — are no longer sufficient for increasingly complex building networks. IoT systems leverage AI and machine learning to move from a reactive or scheduled model to predictive maintenance.

Automated sampling and continuous 24/7 monitoring mean operators no longer wait for lab results to confirm a problem. Real-time reporting ensures teams can act before a minor issue escalates, reducing emergency repairs, downtime and water waste.

Hegde added that it isn’t just about detecting a single out-of-range measurement; it’s about patterns. AI connects multiple indicators to flag potential risks proactively. A data-driven approach can bridge that gap: by continuously measuring metals like iron, copper and lead, operators can see early signs of pipe degradation. Continuous water quality monitoring allows us to anticipate failures before they manifest physically.

By optimizing flushing routines and treatment processes based on real-time measurements, operators can also cut water use, reduce chemical consumption, and support reuse initiatives. As Meena Sankaran pointed out, “IoT shifts water safety from periodic checks to a continuous process, allowing facilities to act in real time while advancing sustainability goals.”

Barriers to adoption

Although IoT and predictive diagnostics can promise transformative benefits for both water safety and plumbing operations, there are several hurdles that can slow adoption in buildings, campuses and municipal systems. Chief among them: upfront cost and ROI perception.

Many building owners and facility managers focus on the initial capital investment for IoT sensors, analytics platforms and installation labor; overlooking the hidden costs of water system failures. Leaks, corrosion-related downtime, regulatory noncompliance and emergency repairs can easily exceed upfront hardware costs.

Operators often think about compliance alone but, when you factor in water savings, reduced chemical usage and avoided emergency maintenance, the ROI becomes much cleaner. Continuous monitoring can prevent minor deviations from escalating into costly repairs, making the business case for smart plumbing all the more compelling.

Another major operational barrier is data overload; turning massive streams of sensor data into actionable insights. Facilities don’t need more dashboards; they need decisions that they can act on as quickly as possible.

AI-driven analytics, automated alerts and compliance-ready reporting can address this challenge. It’s not just raw numbers – it’s meaningful insights that guide maintenance, ensure safety and keep operators focused on what matters. By automating the interpretation of data and tying it directly to operational actions, it’s possible to reduce the burden on staff while still enhancing system reliability.

Integration with legacy plumbing is also an issue. Many existing buildings have aging plumbing infrastructure with varied pipe materials, irregular layouts or older BMS (or Building Management Systems). Integration of IoT devices into these environments requires flexible sensors and careful planning to ensure reliable readings without disrupting operations.

To ensure legacy systems can have smooth operations, companies need to design solutions that work with existing building management systems.

The future of data-driven plumbing

The trajectory of plumbing and water management is moving rapidly toward fully connected, intelligent systems. These innovations promise to reshape compliance, sustainability and operational practices across buildings and municipal systems.

Predictive compliance will play a major role. Regulatory frameworks are increasingly recognizing the value of real-time data over traditional periodic testing. As mentioned earlier, tandards such as LEED v4.1, WELL Building Standard, and updates to ASHRAE 191 emphasize continuous water monitoring, automated reporting and proactive risk management. Real-time systems allow operators to detect early deviations from chemical or microbial standards, reducing violations and improving public health outcomes.

Continuous monitoring is no longer optional for large campuses or critical infrastructure. Automated data collection allows operators to respond before noncompliance occurs, rather than reacting after the fact. Studies in environmental engineering journals show that continuous water quality monitoring can reduce regulatory infractions by 30–50% compared to periodic sampling

IoT-enabled plumbing will also accelerate sustainable water practices. By monitoring flow, temperature and water quality parameters in real time, systems can dynamically allocate water for reuse, recovery or greywater applications. This optimization reduces potable water demand, decreases energy use for pumping and treatment, and supports corporate ESG goals.

As Hegde notes, when you understand water chemistry and system behavior in real time, you can safely reuse water streams for irrigation, cooling towers, or process needs without risking quality or compliance. According to the EPA, smart water systems in commercial buildings can cut water consumption by up to 30% through leak detection, targeted flushing, and reuse strategies.

Emerging technologies are also beginning to enable automated responses that keep systems within safe operating limits without manual intervention. Examples include:

• AI-driven valve control: Automatically isolating leaks or rerouting flow.
• Automated flushing routines: Reducing stagnation in low-usage lines, a key factor in microbial growth.
• Predictive corrosion inhibitors: Injecting chemicals when water chemistry patterns suggest elevated risk of pipe degradation.

These systems integrate predictive analytics with actuation devices, creating a feedback loop where water chemistry, pressure, and flow data directly inform system operations. Research in smart water infrastructure highlights that predictive, autonomous interventions can extend pipe lifespan by 20–30% and reduce emergency repairs significantly, according to the Journal of Water Resources Planning and Management.

The next frontier? Operationalizing plumbing as a managed service. Subscription-based models can combine sensor deployment, monitoring and predictive analytics with professional support from contractors or service providers. This approach shifts the focus from reactive repair to proactive maintenance and long-term system optimization.

Contractors can evolve into long-term analytics partners. By continuously analyzing system performance, they deliver value beyond installation — helping owners optimize water use, reduce risk, and meet sustainability targets.

Connected plumbing signals a fundamental shift in how water systems are managed and maintained. For engineers, contractors and building owners, IoT and predictive analytics deliver a rare combination of operational savings, sustainability gains, and risk mitigation.

From real-time water quality monitoring to autonomous flushing and corrosion prevention, smarter plumbing systems allow operators to prevent failures, optimize reuse and maintain compliance seamlessly. As regulations tighten, ESG pressures grow, and water infrastructure ages, data-driven plumbing is no longer a luxury — it is essential infrastructure for resilient, sustainable and efficient water management.