Industry Blogs

80 Gallon Tanks,  a Mainstay of Residential Construction, are Being Replaced With Smaller Units to Meet Energy Requirements

Over the next decade or so, many veteran plumbers will recall the good old days as the ones where they installed 80-gallon electric water heaters. Once standard in many homebuilding projects, those tanks are products of bygone eras. Like Tyrannosaurus Rex, black and white televisions and 2-hour baseball games, their days have come and gone.

The impetus for the change occurred with the National Appliance Energy Conservation Act of 1987, an act of Congress that regulates energy consumption of specific household appliances. The death knell for the 80-gallon tanks sounded in 2015, impacting all conventional residential electric water heaters with a storage volume greater than 55-gallons. After significant postponement, NAECA III enforcement finally went into effect on January 1, 2022. While the installed 80-gallon electric tanks were allowed to remain in use, many of them have now reached the end of their useful life and need to be replaced.

Water heaters were not alone in the focus of NAECA: dishwashers, air conditioners, refrigerators and nearly every household appliance needed energy improvements, and manufacturers had to make swift changes to their products. The message was clear: reduce the energy demand for every home appliance and do it now.

Canada does not have similar laws – yet — but one project in Nova Scotia included the retrofit of an 80-gallon tank with a 55-gallon tank. The HTP Elevate water heater installed by Adams Heating is much lighter and takes up less space in the mechanical room.

“It’s the equivalent of a much larger tank, but it freed up a lot of space in the mechanical room and is a lot more efficient than a standard water heater,’’ said Brennan Ferguson of Bruce Sutherland Associates, who recommended the HTP Elevate for the installer.

Out With the Old

The retrofit was not uncommon. The century-old, 2,000 square foot home in Mahone Bay used the water heater for domestic hot water. The home’s heat comes from an oil furnace.

While there was no way to determine the precise age of the existing water heater, it had seen better days, to put it mildly. “It was an incredible failure of their onsite tank,’’ Ferguson said. “It was done.”

The homeowner contacted Adams Heating, which contacted Bruce Sutherland Associates. As the HTP representative in Eastern Canada, Brennan Ferguson felt the application called for the 55-gallon Elevate. “With the smaller footprint, and the difficulty in accessing the basement, we thought this might be a good opportunity,’’ Ferguson said.

The space savings in the mechanical room, improved efficiency, stainless steel tank and lifetime warranty of the HTP Elevate made the choice easy for the homeowner. “Going down the stairs with the smaller tank was easy,’’ Ferguson said. “The much harder part was removing the 80-gallon tank. It had been there for some time. It took 3 or 4 guys to manhandle that tank to remove it.”

Unique Features

Several features of the Elevate make it one of the most unique products on the market.

The corrosion-resistant 316L stainless steel tank is an industry rarity but is a top-of-the-line feature. 316L grade stainless steel provides greater corrosion resistance than other types of stainless steel, and is commonly used in marine applications, chemical and petrochemical industries, food processing and pharmaceutical equipment.

The other distinguishing feature is an integrated mixing valve that protects against scalding by safely and consistently mixing outlet water to the desired temperature of the homeowner. Combined with an adjustable thermostat, the Elevate allows for safe and consistent temperature at the faucet while amplifying the total amount of hot water available by safely turning the thermostat up to store water as high as 170°F. An ASSE 1017 anti-scald mixing valve is factory installed, so only inlet and outlet connections need to be established. This valve was chosen for its safety features and proven certification.

“When the water comes up through the mixing valve, it ensures safety on the other end,’’ Ferguson said. “We never want to deliver water more than 120 degrees to the tap. What this concept does is create a tank that delivers hot water reliably with a much smaller footprint and is much more effective than a standard electric water.”

The tank is also lightweight and much easier to handle than glass-lined water heaters and includes low watts density titanium elements that increase corrosion resistance and extend element life.

Game-Changing Legislation

NAECA’s energy efficiency mandate changed the game for manufacturers, who needed to develop different products to comply with the legislation. Manufacturers responded, but now is a critical time in the industry. The lifespan of a typical electric water heater is 8-10 years, and many of the water heaters installed just before the original legislation are on their last legs.

Panic, however, does not have to set in for homeowners or contractors. While there are multiple options, the HTP Elevate is one of the newer products that gives contractors and homeowners peace of mind for the long haul and is easily installed with the added benefits of increased space in the mechanical room, use of premium materials (stainless steel tanks and titanium elements), and a limited lifetime warranty.

“The small footprint and stainless-steel tank make this a really good product,’’ Ferguson said. “It is something we’re going to recommend for a lot of residential retrofits and new installations.”

Thomas Renner writes on architecture, building, construction and other trade industry topics for publications throughout the United States.

For a boiler to operate properly, the liquid it contains must maintain the correct pH levels. If the pH level is not regularly tested and properly maintained, minerals can build up on the inside of the components. Or the water can turn acidic and attack the boiler’s metallic components and piping from the inside out, causing rust to form.

Scale or rust buildup reduces system performance over time. Enough buildup can essentially stop the operation of the system altogether.

Understanding pH levels in hydronic heating systems

Historically denoting “potential of hydrogen,” pH is the measure of how acidic or basic the water inside a hydronic heating system is. According to usgs.gov, the universal reading for pH goes from 0-14, with 7 being neutral. Less than 7 indicates acidity; greater than 7 indicates a base.

• Examples of items that have a pH of less than 7 are black coffee (pH=5), grapefruit juice, soda, or tomato juice (2.5-3.5), and lemon juice or vinegar (2).
• Examples of items that have a pH of greater than 7 would be seawater (8), baking soda (9.5), ammonia solution (10.5-11.5), and liquid drain cleaner (14).

pH is an important indicator of water that is changing chemically. Boiler systems need to have the perfect pH level balance. If the pH goes too high or too low, it can drastically impact a system.

The correct pH level will depend on the metallic composition of the heat exchanger. Some recommended pH levels range from 8 to 8.5. We recommend checking the boiler installation and operation manual to determine the acceptable pH range.  Systems with a cast iron, stainless steel or copper exchanger are resilient and usually have a wide range of acceptable levels. Aluminum is more prone to corrosion and may require a specific pH.

Performing pH testing

Do a visual reading by opening the drain valve and bleeding off some liquid. If it appears clear, proceed with a pH test. As mentioned above, the correct pH level depends on the composition of the heat exchanger.

• How to test pH levels

You can buy test strips that provide a color-coded readout. If you need a more precise reading for an aluminum system, use a digital pH meter.

Hercules Cryo-Tek Test Strips, available in packs of 6 to 10 color-coded and disposable test strips, can simultaneously check both the level of freeze protection (propylene glycol) and the level of corrosion protection in a system.

To conduct the test, drain some water from the boiler and then dip one of the pH test strips into the sample. Once a bit of color starts to pop up, compare the strip to the color chart to determine the pH level.

• How often should you test pH levels?

These are closed systems, so there are usually no external signs of corrosion, making it difficult to spot an equipment leak — unless, of course, water is visibly running onto the floor. (If so, corrosive water inside the boiler is a likely cause.)

This general lack of immediate visibility is why it’s important to test hydronic systems annually. If your locale has hard water or there are conditions causing the water to be more acidic, testing should be done twice a year.

The lack of visibility is also why sampling the water for a test, as described above, is a must: It is the best way to tell if anything is wrong. If rust or sludge appears in your sample, you should test and replace the water.

• What happens if a boiler’s pH is too high or too low?

If you find the pH levels too high, you’ll start to notice scale or limescale buildup in the boilers. Too much mineral buildup will restrict the system’s water flow. Essentially, the effectiveness of the boiler is lessened.

If the pH levels are too low, the water has turned acidic. This leads to rust and corrosion — a serious problem since boilers are typically made of copper, cast iron, and aluminum. As mentioned earlier, enough corrosion can stop system operation altogether.

• How to balance out the pH

Maintenance managers or contractors can use a corrosion inhibitor to balance out the pH — a seamless fix. However, if the buildup or corrosion has been going on for several years, the system will probably not recover with this treatment. Instead, you’ll have to use a cleaner to flush the system to maximize boiler efficiency.

The Hercules^® Boiler and Heating System Cleaner is formulated to clean and condition both steam and hot-water hydronic systems by removing rust, scale, and sludge. The cleaner can also free and lubricate zone valves and help stop priming and foaming with a special anti-foam agent. Ultimately, it is a liquid cleaner and corrosion-prevention treatment.

The Hercules^® Sludgehammer System Restorer & Noise Reducer is another option for maintaining a boiler system. More aggressive than the system cleaner, it also cleans and reduces kettling (bubbling and banging), while restoring system efficiency. Maintenance managers or contractors can pair this product with a corrosion inhibitor for annual heating system-maintenance checks.

If the pH level is off:

• Drain about a gallon of liquid from the boiler and dispose of it.
• Fill a container with a quart of corrosion inhibitor, such as Hercules® Sludgehammer™ Universal Corrosion Inhibitor, and 3 quarts of fresh water. Pump it back into the system and allow it to circulate for about a half-an-hour.
• Test again. Usually, a single dose of inhibitor does the job, but if the reading is still too low, repeat the process

Watch the video below to learn how to remove sludge and corrosion in hydronic heating systems with Sludgehammer.

In conclusion, you must test the pH of boiler systems to maximize their efficiency, using products that can make monitoring pH levels simple and easy. If this testing uncovers damage to the system, there are also ways to alleviate and fix that damage.

But regardless of your boiler’s condition, Oatey products can offer a solution. For more information, go to Oatey.com for their heating chemicals and antifreeze products/resources.

Author’s biography: Sean Comerford is a Technical Applications Manager at Oatey Co. He is a third-generation tradesman with nearly 20 years of plumbing experience, including serving as the lead plumber for commercial/residential new-construction, service and fire protection jobs. He holds a State of Ohio Fire Protection License for Sprinkler and Standpipe.

 

Homeowners in the United States are becoming more inclined to update their residences with the latest smart home technology. Smart homes are the homes of the future and come fully equipped with a range of interconnected devices to offer benefits to the average homeowner.

Smart voice assistants, smart kitchen appliances, smart home security systems, and smart HVAC systems are examples of smart home technologies that homeowners are looking to adopt. It shouldn’t come as a surprise, considering how technology has developed over the years and how the consumer market is becoming more tech-savvy.

As American homes are evolving, how will the role of technicians change? Will technicians learn new skills or technologies to earn business from homeowners? Below is more information about smart home technology and how the role of technicians may change in an interconnected digital era.

Smart Homes Becoming More Commonplace

Statista estimates that the number of smart homes will increase and surpass the 350 million mark by 2023.

Many big tech companies, including Apple, Samsung, Google, and Amazon, are releasing new smart home technologies for customers. Smart TVs, sound systems, voice assistants, security systems, lighting systems, and thermostats are some examples of popular smart home technologies.

Homeowners reap a handful of benefits by using smart home tech. Convenience is likely the primary benefit – most smart home tech can be controlled by one device, usually a smartphone or tablet. These internet-enabled devices connect to hubs or applications for ease of use.

Impact of Smart Home Technology on the Role of Home Technicians

Because so many homeowners are equipping their homes with smart technology, this will likely change, if it hasn’t already, how home technicians do their jobs.

Typically, smart home technology does not have to be maintained or repaired as often as traditional home technology. For example, most systems will alert homeowners in advance of a breakdown, and some will even help homeowners troubleshoot issues.

However, because smart home technology has complex inner workings, technicians may have more difficulty completing repairs. Higher-end equipment often requires more skilled technicians to handle these types of repairs, or those with knowledge of proprietary systems.

What Technicians Need to Know

It will be crucial for technicians specializing in home maintenance or repairs to educate themselves and understand how basic smart home technology works. Service technicians will have to learn how these home devices connect and how each device functions to diagnose and repair issues.

Beyond working on smart technologies within customers’ homes during repairs, technicians may need to rely on these technologies for their own operations. For example, technicians might employ the use of electronic signatures to fuel their business and close deals more efficiently. Or, they may use wearables to capture and improve upon connected data like inventory and location information.

One major reason technicians will need to become more knowledgeable about smart home tech is that homeowner expectations are changing. A technician who has expanded their skillset to repair smart home tech will be in higher demand than those who do not.

As smart homes go mainstream, technicians capable of working on these complex smart home technologies will be well-positioned to offer their repair services, allowing their business to grow and generate more revenue.

Technicians: Keep Your Skills Relevant in the Age of Smart Home Technology

All technicians need to stay up-to-date with the latest technologies. Whether they specialize in HVAC, lighting, or plumbing, modern technicians should be aware of the adoption of smart home technologies to better prepare themselves for these repairs.

Guest Blogger: April Miller is a managing editor at ReHack.com who specializes in engineering and construction technology. You can find her work published on sites like Open Data Science and The Society of Women Engineers.

 

 

Speed and accuracy are the name of the game when it comes to a successful piping installation and a thriving business. Whether you’re installing potable plumbing or hydronic piping, the faster and more precise the job, the more time and money you potentially have to work on other projects.

While there are hundreds of tips and tricks out there to make your installs faster, easier, and more effective, I’m going to concentrate on the following three methods almost any plumbing or mechanical contractor can use to bring greater productivity to projects.

Flexible PEX pipe with bend supports

If you’ve never heard of PEX, it’s an acronym for crosslinked polyethylene. It’s a flexible, durable plastic piping product that provides numerous benefits over rigid CPVC or metallic systems, including faster installs, zero corrosion, and freeze-damage resistance.

Many residential contractors are already using PEX (considering it’s the most installed piping system for new-home construction over copper and CPVC combined). However, PEX is still a relative newcomer in the commercial industry.

The biggest benefit of PEX is its flexibility, which allows you to simply bend the pipe with each change in direction. With a tight bend radius of six times the pipe’s diameter, you can practically make 90-degree bends without the need for a fitting.

For times when you do have a tight bend that needs to stay in a particular place, PEX manufacturers offer bend supports. For those of you that prefer to watch rather than read, here’s a video that explains bend supports in detail.

These helpful products are available for ⅜”, ½”, ⅝”, ¾”, or 1″ PEX pipe. They hold the bend in place at the proper angle and take a fraction of the time compared to making a 90-degree elbow.

Most contractors agree that using flexible PEX with bend supports can eliminate most fittings in smaller-diameter pipe sizes 1″ and down, saving up to half the install time of a rigid piping system.

Expansion tools

When it comes time to make a connection with PEX pipe, the professionals’ choice is PEX expansion. Note that expansion connections are only designed for PEX-a pipe. If you’re using PEX-b or PEX-c pipe, you’ll need to use a different fitting type as PEX-b and PEX-c pipes aren’t made to expand like PEX-a pipe, and they will experience microcracking during expansion.

Expansion connections require one simple tool that expands the pipe and an expansion ring before inserting a fitting. As the pipe and ring shrink back down around the fitting, it creates a solid, strong seal that can withstand up to 1,000 pounds of radial force. It’s quick and easy to do and simple to learn, so it’s highly beneficial with the skilled-labor shortage that’s challenging the trades. Here’s a quick, 20-second video on how to make a connection.

Now, to make installs even faster, expansion tools have advanced to make connections even quicker. For up to 1″ connections, the Milwaukee^® M12 FUEL™ ProPEX^® Expander with RAPID SEAL™ Heads is the fastest tool yet — with up to 65% faster sealing times compared to previous models.

For larger-diameter pipe connections, the new Milwaukee M18 FUEL™ ProPEX Expander with ONE-KEY™ is taking commercial installs to a new level by offering 3X faster 2″ connections. To watch how much faster, check out this video from Milwaukee Tool.

Prefab

Finally, let’s talk about prefabrication. This is becoming a big trend for national residential builders or large commercial projects that have a lot of repeatability on the project. By prefabbing certain sections of a project, it can shave days, weeks, or even months off a timeline, depending on how big the project.

Prefabricating piping assemblies in a controlled factory environment not only adds more efficiencies, it also provides an additional benefit of greater accuracy. By doing a job repeatedly, it hones the skill and gives installers greater confidence in their work.

Plus, having rows and rows of prefabbed piping assemblies in a shop environment makes it a lot easier to perform quality checks. Instead of walking for miles on a job site, a supervisor can save significant time simply walking a shop floor.

And here’s another area where flexible, durable PEX provides additional benefits. Transporting prefabbed PEX piping assemblies is much easier than transporting rigid assemblies that can crack or break. Because PEX is super flexible, it can withstand the rigors of being transported to a job site without worry.

So, there you have it…just a few ideas to keep in mind the next time you have a project with a tight deadline, and you’re squeezed on time and skilled labor. Every little bit helps when it comes to adding productivity to projects. If you have other ideas, I’d love to hear them. Feel free to email me at kim.bliss@uponor.com.

Kim Bliss is the technical and marketing content manager at Uponor. She can be reached at kim.bliss@uponor.com.