Estimating the Lifespan of a Water Heater

by Nick Gromicko, CMI® and Barry Fowler

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While the typical water heater has a lifespan of about 10 years, careful consideration of the factors that pertain to its lifespan can provide the InterNACHI home inspector and the homeowner with information about the potential costs that would be incurred by replacing the water heater. These factors include: correct installation; usage volume; construction quality; and maintenance.

Correct Installation

Water heaters should be installed upright in well-ventilated areas -- not just for fire safety requirements and carbon monoxide buildup, but also because poor ventilation can shorten the lifespan of the water heater. 

A water heater should not be placed in an area susceptible to flood damage. Water can rust out the exterior and pipes, decreasing the life expectancy and efficiency of the unit.  A water heater is best placed in an easily accessible area for maintenance.  It should also be readily visible for fire and health-hazard requirements.

The inspector may wish to inquire as to whether the water heater was installed professionally. Homeowners may install their own units to save money, but the installation of a tankless gas water heater, for example, requires more skill than the average DIY task.  In the case of the owner-installed tankless gas water heater, the home inspector may want to check the gas pipe work for leaks to determine whether there is adequate ventilation.

Usage

The life expectancy of the water heater depends a great deal on the volume of water used. Using large quantities of water means that the water heater will have to work harder to heat the water. In addition, the greater the volume of water, the greater the corrosive effect of the water will be.

Construction Quality of the Water Heater 

As with most household systems and components, you get what you pay for in a water heater. Cheaper models will generally have a shorter lifespan, while more expensive models will generally last longer. A good indication of a water heater’s construction quality is its warranty.  Longer warranties naturally imply sounder construction. According to a 2007 Consumer Report that deconstructed 18 different models of water heaters, it was determined that models with longer warranties invariably were of superior manufacturing quality, with nine- and 12-year models typically having larger or higher-wattage heating elements, as well as thicker insulation. Models with larger heating elements have a much better resistance to mineral buildup or scum. 

Pay attention to the model's features.  Porcelain casing, for example, provides an additional layer of protection against rusting, and a greater level of heat insulation. Some models come with a self-cleaning feature that flushes the pipes of mineral deposits, which is an important consideration in the unit's lifespan.  Models with larger or thicker anodes are better-equipped to fight corrosion.

Maintenance and Parts Replacement

The hardness of the water is another consideration when looking at estimating the lifespan of a water heater.  In areas where there is a higher mineral content to the water, water heaters have shorter lifespans than in other areas, as mineral buildup reduces the units' efficiency. Even in areas where the water is softer, however, some mineral deposition is bound to occur.  A way to counteract this mineral buildup is to periodically flush the water heater system, which not only removes some of the buildup, but, in tank systems, the process heats the water in the tank. High-end models typically come equipped with a self-flushing feature.  In models for which manual flushing is required, it is important not to damage the water heater valve, which is usually made of plastic and is easy to break.

Although an older model may appear to be well-maintained, a question arises:  Is the maintenance worth it? Warranties often exclude labor costs, so a good rule to follow is that if the total repair cost per year is greater than 10% of the cost of buying and installing a new water heater, it is probably not worth replacing damaged parts. 

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It is debatable whether the cost in time and money of replacing the sacrificial anode in a water heater is worth the benefit of prolonging the use of the existing water heater by a couple of years. In the tricky process of emptying the tank and replacing the anode, it is easy to damage the unit, and, as some warranties can be voided by anode replacement, the cost of future repairs or maintenance that might otherwise be covered must be considered. 

In summary, there is a variety of factors influencing the lifespan of a water heater. Beyond the basic telltale signs, such as a leaky puddle under the heater or cold showers in the morning that indicate that a new water heater is probably in order, the homeowner should consider the age and warranty of the model, and carefully weigh the cost-benefit of maintaining an existing heater versus buying a new one.

It is not uncommon for property owners or facility managers to wait until a boiler completely breaks down before replacing the unit. To make things worse, these types of failures happen when there is real need for heat (for instance, a very cold day) and since the failure is unexpected, there are rarely emergency funds allocated to fix the problem.

Suddenly having to shell out unplanned capital to replace a boiler with avoidable damage is no fun. The first tip to helping owners avoid this is to implement a regular maintenance and inspection program with a qualified contractor. These inspections of the boiler system should occur at least once a year. In order to ensure the owners maintain their full-warranty, be sure to recommend Genuine Weil-McLain Parts.

During the review, be sure to include the following:

• Make sure the shut off valves function properly. Check for water leakage. If there is any sign of potential leakage, have a leak test performed.

• Check the refractory for integrity to ensure it is properly protecting critical portions of the boiler.  Check for broken pieces or even cracks, and repair if needed.

• Check the functioning of controls, safety devices, and indicators, including the low-water cutoff devices and regulators, pressure gauge, safety valves, and the pressure release valve. Any that are not working properly puts the boiler at risk of major structural damage.

• Check your fuel feed system and burners, particularly if your boilers use liquid fuels. They should be inspected and cleaned. Not doing so will result in inefficient combustion and heat transfer, resulting in higher fuel costs and less effective heating. Related to this is to clean or replace any fuel filters so as to maintain effective fuel flow, without which damage could occur.

• Be sure to clean boiler heat transfer surfaces regularly to remove buildup. In the case of an oil-fired boiler, there may be soot residue.  Soot can act as an insulator which cuts down on the efficiency of the heat transfer between combustion gas and steam or hot water generation.

When inspecting your boiler, remember to look for any signs of corrosion, overheating, or erosion, as well as any leaks from the boiler or external piping. These items can be signs that the boiler is not working properly and should be repaired immediately.
 

In the event that you’ve missed a few regular annual inspections, here are seven telltale signs that it’s time to replace your boiler:

1. Age: Condensing boilers haven’t been on the market for a long time and therefore it is hard to predict their longevity. With proper maintenance, they are expected to last at least 15 years or longer. Weil-McLain boilers come with a 10 year non-prorated heat exchanger warranty for commercial boilers, 12 year non-prorated heat exchanger warranty for residential boilers and two year parts warranty for both categories. Cast iron boilers, on the other hand, should be considered for replacement if they have been operating for more than 20 or 30 years. Some of these boilers can last even up to 50 years or longer, but even with decent annual maintenance, their efficiencies are much lower than today’s cast iron boilers. Often times, the energy savings from a new boiler replacement alone practically pays for the cost itself within a year or two. Weil-McLain cast-iron residential boilers come with a 20 year non-prorated heat exchanger warranty and two year parts warranty.

2. Energy Expenditures: Be mindful of any increases in energy expenses. If energy bills are slowly rising it may be due not only to the age of the boiler but also due to increasing costs of the boiler maintenance. If a boiler requires constant servicing, the system has likely become less efficient. One should consider upgrading to a more reliable, durable unit such as a cast iron unit. Additionally, a noisy unit also may be a sign that it’s time for an upgrade.

3. Increased frequency of failures: This is a clear indicator that the unit is due for either a major overhaul or replacement.

4. Discoloration: Yellow flames on gas burners and black soot on oil boilers indicate that the fuel is not burning properly and is creating carbon monoxide. It is highly recommended that property owners install carbon monoxide detectors.

5. Leaks: A boiler that leaks or requires additional make-up water could be nearing the end of its lifecycle. By replacing the existing unit, the building manager or owner can avoid costly floods and critical boiler or property damage.

6. Comfort: If you notice that some rooms in a building are too hot or too cold or have varying temperatures throughout the day, it’s possible that the unit and its controls are no longer effective or the facility may benefit from more efficient controls.

7. Quality: If your boiler isn’t a Weil-McLain, it may be time to upgrade with our innovative product line. From the longevity of a standard efficiency boiler to the long-term energy savings from a high efficiency boiler, Weil-McLain offers reliable, effective and quality solutions for any application.

Even if a boiler isn’t immediately failing, upgrading to a newer system can offer significant benefits. By planning the change, rather than facing an emergency in the throes of winter, building owners and managers can realize energy savings, a more comfortable facility, tenant retention, improved heating reliability and increased property value. 

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