When a commercial water heater malfunctions, it can disrupt operations, cause customer dissatisfaction, and lead to expensive repairs. Businesses in St. Louis—whether it’s a hotel, restaurant, office building, or industrial facility—depend on hot water for a variety of essential functions. If your water heater is on the fritz, understanding the common causes of water heater problems can help you take preventive measures, avoid costly downtime, and extend the lifespan of your system.
At PK Plumbing, we specialize in both residential and commercial plumbing, and we’ve seen it all when it comes to water heater issues. Here’s a look at the most common causes of commercial water heater problems and how they can be addressed:
1. Sediment Build-Up
Over time, mineral deposits like calcium and magnesium accumulate at the bottom of water heaters, especially in areas with hard water, such as St. Louis. This sediment build-up can cause several issues, including:
- Reduced Efficiency: Sediment insulates the heating elements, meaning your water heater has to work harder to heat water, resulting in higher energy bills.
- Overheating: The heating element may overheat due to insufficient contact with water, leading to system failure or premature burnout.
- Noisy Operation: You may hear popping or rumbling noises, which is the sound of water trapped under the sediment, causing the tank to overheat.
Solution: Regularly flush your water heater to remove sediment build-up and ensure the system operates efficiently. Commercial water heaters, depending on their size, should be flushed at least once a year. This can prevent long-term damage and improve water quality.
2. Thermostat Malfunctions
A malfunctioning thermostat can lead to inconsistent water temperatures or even cause the water heater to stop working altogether. Thermostats control the water temperature, and when they fail, it can lead to:
- Overheating or Scalding: If the thermostat is stuck on a high temperature, it could cause dangerously hot water to flow through your pipes, risking burns to employees, guests, or customers.
- Insufficient Hot Water: A faulty thermostat can cause your water heater to heat water to an insufficient temperature, leaving your business without the hot water it needs.
Solution: Have the thermostat calibrated regularly and replace any faulty components. In some cases, the entire thermostat may need to be replaced if it’s beyond repair.
3. Faulty Heating Elements
The heating elements are responsible for warming the water inside the tank. If one or multiple elements fail, your water heater will struggle to heat water or will stop providing hot water entirely. This is often a problem in older commercial water heaters.
Solution: Regular inspection of the heating elements is essential. If an element is burned out or malfunctioning, it will need to be replaced. Hiring a professional plumber for regular maintenance can help catch this issue early before it causes a complete system failure.
4. Leaking Tanks
Water heater tanks can corrode over time, especially if they’re older or poorly maintained. Corrosion can lead to water leaks, which not only reduces the efficiency of the water heater but also poses a risk of water damage to your property.
Solution: If you notice water around the base of the water heater, it could be a sign of a leak or internal corrosion. In some cases, a leak can be repaired, but in more severe instances, the tank will need to be replaced. Annual inspections can catch signs of corrosion before they escalate.
5. Gas or Electrical Supply Issues
For gas-powered water heaters, a failure in the gas supply line can cause the system to stop working. Similarly, electric water heaters can experience power supply problems that prevent them from heating water.
- Gas Supply Problems: Issues such as a clogged pilot light, a malfunctioning gas valve, or gas line blockages can cause the water heater to malfunction.
- Electrical Supply Problems: Faulty wiring, circuit breakers, or tripped fuses can prevent an electric water heater from functioning properly.
Solution: For gas-powered water heaters, ensure the gas supply is functioning properly and check for any blockages. For electric models, inspect the electrical connections, fuses, and circuit breakers. However, it is best to have these types of issues handled by professionals, in order to ensure everyone’s safety.
6. Inadequate Insulation
If the pipes leading to and from the water heater aren’t properly insulated, the water can lose heat as it travels through the system, resulting in temperature fluctuations. This can be especially problematic in colder months.
Solution: Insulate your water pipes to minimize heat loss. Proper insulation can improve efficiency and help maintain the water heater’s performance, especially in commercial spaces with high water usage.
7. Overuse or Undersized Water Heater
In high-demand commercial environments, your water heater may be undersized for your needs. If you’re using more hot water than the system can provide, it will struggle to keep up with demand, leading to inadequate hot water and potential system failure.
Solution: Ensure your water heater is appropriately sized for your business’s needs. If your usage has increased, it may be time to upgrade to a larger model or add an additional unit to meet the demand.
8. Old Age and Wear and Tear
Finally, as with any appliance, commercial water heaters have a finite lifespan. Over time, parts can wear down and the system can become inefficient. A water heater that’s more than 10–15 years old may begin to experience more frequent breakdowns and require replacement.
Solution: If your water heater is nearing the end of its lifespan, it’s a good idea to start planning for a replacement. Upgrading to a newer, more efficient model can reduce energy costs and prevent emergency failures.
How to Prevent Water Heater Problems in Your Commercial Facility
The best way to prevent common water heater problems is through regular maintenance. At PK Plumbing, we recommend scheduling annual inspections for your commercial water heater to catch potential issues early. Regular maintenance services include:
- Flushing the tank to remove sediment
- Inspecting the thermostat, heating elements, and electrical or gas connections
- Checking for leaks or signs of corrosion
- Testing the water temperature and adjusting as necessary
By staying proactive, you can ensure your water heater operates at peak efficiency, reducing the likelihood of unexpected problems and costly repairs.