My Water Heater Rusted Out & Flooded My Basement — Then Things Kept Going Wrong

Welcome to Domestic Disasters, where we take a look at some of your worst mess-ups and grossest finds. We take them to the experts to find out how big of a problem they are and how expensive they are to fix.

Last month, after filling the bathtub for his young daughter, Ethan discovered that the water wasn’t hot. When he opened the utility closet to investigate, he found a puddle covering most of the floor.

Being handy with household DIY tasks, he immediately knew what the problem was: the water heater tank had rusted out. The only fix was to install a new one.

What They Tried

Ethan’s first priority was to close the supply line valve to prevent the tank from refilling. Then, before heading to the home improvement store, he connected a hose to the spigot at the bottom of the tank to drain the remaining water.

He figured it would be empty by the time he got home, but when he returned, water was still draining out. That meant the supply line valve wasn’t closing, so the only solution was to shut off the main water to the house.

The next morning, Ethan successfully installed the new heater, then enlisted the help of his father-in-law to haul the old one up the stairs. Because it weighed more than 120 pounds, that ended up being the most challenging part of the ordeal, he says. It was also messy, with water leaking out along the way, despite their efforts to stem it with a plastic bag.

“If there’s a silver lining here, it’s that we were home when this happened,” he says.

Ethan is a confident DIYer, but did he actually approach the problem the right way? And could he have taken steps to prevent it?

A Pro Weighs In On What Went Wrong

Both gas and propane water heaters typically last 10 to 15 years before succumbing to corrosion. Since Ethan’s tank was 21 years old, the experts we talked to were not surprised that it had failed. Neither was Ethan. Also, the problem was likely compounded by geography. Ethan lives in Minnesota, and cold climates cause water heaters to work harder.

As for the faulty valve, it is usually caused by rotted gaskets or buildup in the line that prevents it from sealing. “It’s actually pretty common on water heaters that are older than ten years,” says plumber Travis Hargrave.

Did the Homeowners Get it Right?

Mostly. After realizing the supply line valve was faulty, he was correct in shutting of the main water to the house. “That’s your only move, and hesitating even 10 minutes can mean hundreds of gallons on the floor,” says plumber Brendan Tonks.

But Ethan also got lucky in that respect, says plumber Kolby Barnes. Ethan’s home is a 1940s bungalow, and many older homes like his use gate valves (rather than ball valves) for the main water shutoff. Similarly to supply line valves, they are vulnerable to buildup that prevents them from closing.

What Ethan didn’t get right, however, was neglecting to replace the aging water heater before it failed. It also would have been wise to install a smart device that can monitor for leaks and shut off the water in an emergency, says Barnes.

“The smart device isn’t necessarily a mistake on his part, since such devices are relatively new, but now that your readers know about them, it would be a mistake not to consider installing one to prevent both catastrophic leaks and slow, hidden ones,” says Barnes.

What Would a Pro Have Done Differently?

All of the pros we talked to pointed out one important step that Ethan missed — shutting off the gas or electricity to the water heater before touching anything, in order to prevent a safety hazard.

The Panic Meter

We rank Domestic Disasters on a four-point scale.

• Do It Yourself: The easiest issues to fix. You can handle it all on your own.
• Phone a Friend: This issue might require a little outside assistance.
• Call a Pro: This situation warrants professional assistance.
• SOS: Problems that are so dangerous, you’re directly at risk of injury or worse.

Whether to DIY a water heater replacement or call in a pro depends on your confidence level. “I don’t recommend a DIY fix because water heaters involve gas and electrical components that can be dangerous if not handled correctly,” says Tonks.

However, Ethan says it is a relatively easy task for DIYers, especially if they use shark bite connections. “As long as you have a helper who can help lug the old one out and the new one in, it should be a two or two-and-a-half-hour job,” he says. “And half of that is cleaning up.”

The Cost Differential

It is possible to extend the life of a water heater by replacing the internal anode rod, which helps prevent corrosion, every few years. As a DIY fix, this usually runs between $20 to $50, or $150 to $600 if you call a pro. Expect similar costs for replacing the valve.

If you have to replace the whole water heater, a DIY fix will run around $700, vs. $1,500 to $3,500 for a pro.

Keep in mind, too, that if you don’t catch and fix a leak promptly, the resulting flood damage could run into the thousands to tens of thousands of dollars for water damage and mold remediation.

How to Fix Water Heater Problems the Right Way

Before you enter the room, turn off the power or gas to the water heater, depending on its style. That will prevent electrocution and fire danger. In extreme cases, water heaters can also explode if the tank is empty but still heating up.

Then:

• Turn off your home’s main water supply.
• Drain the tank.
• For valve issues, cut out the old one and install a new one. Leave it closed for now, and do not over-tighten, says Hargrave.
• Replace the water heater.
• If your heater is gas, test the gas line with soapy water to make sure it’s not leaking.
• Turn the water back on to the home.
• Confirm there are no leaks in the valve or other pipes.
• Turn on the new valve at the water heater.
• Fill the new tank with water. Use a pop-off emergency valve to release the air while filling, says Hargrave. “When water flows through, the tank is full and you can turn it back off.”
• Run hot and cold faucets downstairs to remove air pockets and confirm the heater is completely full.
• Check the water heater valve for leaks again.
• Turn the gas or electricity back on. If you have a gas heater, pay special attention to the manufacturer’s safety instructions, which are usually posted on the heater.

How to Prevent Water Heater Problems

• Open and close the supply line valve every six months to prevent buildup.
• Replace the anode rod every three to five years.
• Know where your main home water shutoff valve is located, and inspect the seals yearly.
• If your main shutoff uses a gate valve, consider replacing it with a ball valve.
• Replace your water heater every 10 to 15 years, especially if you have hard water or live in a cold climate.
• Install a smart device that detects leaks and shuts off the water supply. Barnes recommends the Moen Flo unit. Adding one might also qualify you for a homeowner’s insurance discount.
• If your home is older and doesn’t have a built-in water heater drain, set up a floor drain pan.

Ethan also warns about a mistake he nearly made: “A lot of the newer, more energy-efficient gas models also need an outlet, but I didn’t have that available in my space,” he says.

Finally, when it’s time to replace your water heater, if you’re considering switching from gas to electric, or to a tankless or heat-pump model, plan for that shift well before your old one fails, as you will likely have to address space, venting or electrical system upgrades.

What the Homeowner Learned

“It’s definitely a DIY job,” says Ethan. “You don’t need many tools, and it’s very approachable. But if there’s one takeaway, it’s to get a helper, not only for your back, but because you’re gonna put water on the floor, so you wanna move the old one out quickly.”

As for whether Ethan will preemptively replace this water heater in 10 or 15 years, he says, “probably not. I’m one of those people who doesn’t fix it until it’s broken. I just hope it doesn’t happen while I’m in Disney World or something like that.”

About the Experts

• Kolby Barnes is a second-generation plumber, service technician and plumbing trainer manager at Service Force Plumbing in Maryland.
• Travis Hargrave has more than 30 years of plumbing experience and runs Hargrave’s Plumbing in Louisiana.
• Brendan Tonks is a licensed plumber and gasfitter, and director of Steve Bennett Plumbing in Australia.

Do you have a Domestic Disaster experience you’d like featured on Family Handyman? Email us your experience at fhmfranchises@tmbi.com.

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