Common Causes of Water Heater Failure and How to Avoid Them
Water heater failures are often caused by sediment buildup, faulty thermostats, leaks, and aging components. These problems can disrupt your daily routine and lead to costly repairs if not addressed. Whether you are a homeowner or a business owner, understanding these common causes and taking preventive measures can help avoid major water heater breakdowns and extend its lifespan.
Considered essential for daily tasks like showering, cleaning, and heating, any failure in a water heater, whether tankless, storage tank, heat pump, solar, or hybrid, can cause significant disruptions. According to the Institute for Business & Home Safety (IBHS), around 25% of U.S. households experience water heater failures each year, with 69% of these failures resulting from slow leaks or bursts, leading to substantial water damage.

Routine maintenance is key to preventing such failures. Regular inspections, ensuring proper temperature settings, and resolving minor issues before they escalate can all play a significant role in improving your water heater’s efficiency and performance.
Neglecting these preventive measures, however, can lead to no hot water, water damage, and increased energy costs. For instance, a malfunctioning thermostat can lead to inconsistent water temperatures, while sediment buildup can cause the system to overheat. Water heaters typically last between 8 and 12 years, and beyond this period, the likelihood of failure increases. By staying proactive with maintenance, you can avoid costly repairs and ensure your water heater continues to run smoothly.
6 Common Causes of Water Heater Failure
Several factors contribute to water heater failure, including sediment buildup, faulty thermostats, leaking tanks, faulty heating elements, power or gas supply issues, and the age of the unit. These issues often affect specific components of the water heater: sediment typically accumulates at the bottom of the tank, while faulty thermostats are usually located in the control panel, and leaking tanks are often caused by corrosion inside the tank. Power or gas supply issues involve electrical connections or gas lines, while aging affects the overall performance and efficiency of the unit.
In the section below, we will discuss the top 6 causes of water heater failure in more detail and explore how you can prevent each issue.
- Sediment Build-up
- Faulty Thermostat
- Leaking Tank
- Faulty Heating Element
- Power or Gas Supply Issues
- Age of the Water Heater

1. Sediment Build-Up
Sediment buildup is a common issue, particularly in areas with hard water. Minerals such as calcium and magnesium settle at the bottom of the water heater tank over time, forming a layer of sediment. This layer creates an insulating barrier that prevents the heating elements from efficiently warming the water, which forces the system to work harder. The longer the sediment accumulates, the greater the energy consumption, leading to higher utility bills. Additionally, sediment buildup can cause overheating, potentially leading to the corrosion of the tank and causing leaks or complete failure.
Solution:
To prevent the negative effects of sediment buildup, it is important to implement regular maintenance practices. Below are key measures to help keep your water heater functioning efficiently:
- Flush the tank: Perform an annual flush to remove sediment and keep the system running efficiently.
- Install a water softener: Use a water softener to reduce the minerals in hard water that contribute to sediment buildup.
- Monitor signs of buildup: If you notice fluctuations in water temperature or longer heating times, sediment may be the cause.
- Consider self-cleaning models: Invest in newer water heaters with built-in self-cleaning features to reduce sediment accumulation.
2. Faulty Thermostat
A thermostat regulates the water temperature inside the tank. A faulty thermostat can lead to inconsistent water temperatures, causing either scalding hot water or lukewarm water at best. When the thermostat is malfunctioning, it might fail to regulate the temperature correctly, leading to wasted energy and discomfort. In some cases, the thermostat can become stuck in the “on” position, causing the water heater to overheat. This not only wastes energy but can also damage the heating elements, shortening the lifespan of your water heater.
Likewise, if water temperatures fluctuate unexpectedly, it can lead to safety risks, especially in commercial settings where water needs to be at a consistent temperature for sanitation or heating purposes.
Solution:
To avoid thermostat-related issues, regular checks and adjustments are essential. Here’s how you can address and prevent thermostat problems:
- Check and adjust the thermostat: Set your thermostat to 120°F for optimal performance and safety.
- Test functionality regularly: Periodically test the thermostat to ensure it is accurately regulating the temperature.
- Replace when faulty: If the thermostat is malfunctioning, replace it promptly to avoid further damage to the unit.
- Ensure proper calibration: Have the thermostat calibrated to avoid temperature fluctuations.
3. Leaking Tank
Leaks in the water heater tank are often caused by corrosion or physical damage. Over time, the inside of the tank can rust due to the constant exposure to water, leading to cracks or holes in the tank. This corrosion accelerates as the unit ages, especially if it is not maintained properly. When the tank begins to leak, it can result in significant water damage to the surrounding area, including flooring, walls, and ceilings. In addition to the immediate damage, a leaking tank can also reduce the water heater’s efficiency, causing it to work harder to maintain the desired temperature.
Solution:
To prevent leaks and the potential for water damage, costly repairs, and replacement of the entire unit, regular maintenance and inspections are critical. Here’s how you can minimize the risk of leaks:
- Inspect regularly: Look for any signs of rust or water pooling around the base of the tank.
- Replace the anode rod: The anode rod helps prevent corrosion. Replace it every 2-3 years to prolong the life of the tank.
- Monitor water pressure: High water pressure can contribute to leaks. Ensure that your water pressure is within the recommended range for your unit.
- Consider replacing old units: If your water heater is over 10 years old, consider replacing it to avoid leaks and further damage.
4. Faulty Heating Elements
Heating elements are responsible for heating the water inside the tank. Over time, these elements can wear out or become damaged due to excessive use, general aging, or mineral buildup. When a heating element fails, the water heater will either produce no hot water or inconsistent temperatures. In some cases, sediment buildup on the heating elements can also reduce their effectiveness, causing them to overheat or malfunction.
The impact of faulty heating elements can range from discomfort due to no hot water to system failure. Repairing or replacing a faulty heating element is often more cost-effective than letting the issue persist, which could lead to further damage.
Solution:
To ensure your heating elements are functioning properly and avoid costly repairs, consider the following preventive measures:
- Inspect the heating elements: Regularly check the heating elements for any visible signs of damage or wear.
- Clean the heating elements: Remove any mineral buildup from the elements to improve their performance and longevity.
- Replace damaged elements: If the elements are malfunctioning, replace them promptly to avoid further system damage.
- Test functionality: Use a multimeter to test whether the heating elements are heating the water properly.
5. Power or Gas Supply Issues
Power or gas supply interruptions can cause your water heater to stop functioning altogether. For electric water heaters, power surges, tripped circuit breakers, or faulty wiring can prevent the system from receiving power. Gas-powered water heaters can experience disruptions if there are issues with the gas line, such as a blocked pipe, a faulty valve, or an unlit pilot light. In both cases, the water heater will be unable to heat water, leaving you without hot water until the issue is resolved.
When power or gas supply issues occur, they prevent the water heater from working and cause more serious problems, such as electrical shorts or gas leaks.
Solution:
To ensure that your water heater has a stable power or gas supply, follow these preventive steps:
- Check power connections: Ensure the circuit breaker is not tripped, and inspect wiring for damage or wear.
- Inspect the gas line: Regularly check for blockages or leaks in the gas line, and ensure the gas supply is consistent.
- Test the pilot light: For gas heaters, ensure the pilot light is lit and functioning properly.
- Consult a professional: If you are unable to resolve electrical or gas issues, contact a technician to avoid further complications.
6. Age of the Water Heater
As water heaters age, their efficiency decreases, and they become more prone to failure. Most water heaters last between 8 and 12 years. After this time, the system is more susceptible to issues such as sediment buildup, corrosion, and worn-out components. An old water heater will not only work less efficiently but may also increase your utility bills due to higher energy consumption. In some cases, aging units may suffer from leaks or complete breakdowns, requiring expensive repairs or replacement.
Ignoring the age of your water heater can lead to inconvenient failures at the worst possible time, potentially causing significant water damage and downtime.
Solution:
To manage the aging of your water heater and prevent breakdowns, consider these steps:
- Schedule regular inspections: Have your water heater inspected by a professional at least once a year to detect issues early.
- Replace when necessary: If your water heater is over 12 years old, consider replacing it with a newer, more energy-efficient model.
- Extend lifespan with maintenance: Perform regular maintenance, such as flushing the tank and replacing the anode rod, to extend the life of your water heater.
Preventive Measures to Avoid Water Heater Failure
To prevent water heater failure, it is essential to implement regular maintenance practices, including routine maintenance, regular inspections, replacing anode rods, upgrading heating elements, setting proper temperatures, and insulating the unit. These proactive steps help ensure your water heater runs efficiently, extends its lifespan, and reduces the likelihood of costly repairs.
Schedule Your Water Heater Maintenance
Use the calendar below to schedule your water heater maintenance tasks. You'll receive an email reminder before the task is due!
Routine Maintenance
Maintaining a water heater involves more than just fixing problems when they arise. It requires regular upkeep to ensure everything runs smoothly. Flushing the tank annually, checking the thermostat settings, and ensuring there are no leaks can go a long way in preventing inefficiency and potential failures. These simple tasks can prevent larger, more expensive issues down the line.
To stay on top of maintenance and keep your water heater functioning at its best, consider the following steps:
- Flush the tank annually to remove sediment buildup that can affect heating efficiency.
- Inspect thermostat settings to ensure the temperature is set to 120°F for safety and efficiency.
- Check for leaks by regularly inspecting the tank and pipes for visible signs of water leakage.
Regular Inspections
Performing routine inspections is crucial to identifying potential issues early before they become major problems. By examining the water heater and listening for unusual noises, you can catch signs of wear, sediment buildup, or malfunctioning components that might lead to system failure. Regular inspections help ensure the system remains in good working order and prevent costly repairs.
Here are key inspection tasks to keep your water heater in top condition:
- Inspect the tank for rust and look for any visible signs of corrosion or rusting.
- Listen for unusual sounds like rumbling or popping noises, which may indicate sediment buildup.
- Check water pressure to ensure it is within the recommended range and avoid unnecessary stress on the system.
Replacing Anode Rods
The anode rod plays a key role in preventing internal corrosion within your water heater. It attracts corrosive elements, preventing them from attacking the steel tank. As the rod wears down over time, it becomes less effective, and failing to replace it can lead to rust and eventual failure of the unit.
To ensure your water heater stays protected, follow these simple steps for managing the anode rod:
- Check the anode rod every 2-3 years to ensure it has not deteriorated or worn down.
- Replace the anode rod as needed to continue protecting the tank from corrosion.
- Use a magnesium anode rod for improved performance in areas with hard water.
Upgrading Heating Elements
Heating elements are essential for efficiently heating water, but they can degrade over time, reducing their effectiveness. Regular wear and sediment buildup can cause the elements to work harder than necessary, resulting in increased energy consumption and a lack of hot water. Upgrading or replacing old elements can improve energy efficiency and restore proper water heating performance.
To keep your water heater working efficiently, consider the following actions:
- Replace aging heating elements if they are more than 5-7 years old or showing signs of wear.
- Inspect and clean the elements to remove sediment buildup and maintain their effectiveness.
- Test the heating performance by checking the water temperature regularly to ensure the elements are working properly.
Setting Proper Temperature
Setting the correct temperature on your water heater’s thermostat is a simple yet effective way to avoid overheating or underheating. Keeping the temperature at 120°F provides adequate hot water while preventing energy waste and reducing the risk of scalding. Adjusting the temperature based on household needs can help balance energy savings with comfort.
To make sure you are setting the temperature correctly, follow these tips:
- Set the thermostat to 120°F for energy efficiency and safety.
- Avoid setting the temperature too high to prevent wasted energy and minimize the risk of burns.
- Test the water temperature regularly to ensure it is at the right level for your needs.
Insulating the Heater
Adding insulation around your water heater and its pipes can significantly improve energy efficiency. Insulation helps to minimize heat loss, keeping the water at a consistent temperature without requiring the heater to work as hard. This simple step can lower energy bills and extend the heater’s lifespan, especially in colder environments.
To maximize insulation benefits and reduce energy consumption, follow these preventive actions:
- Insulate the tank with an insulated blanket to reduce heat loss from the tank.
- Insulate hot water pipes to keep water warm as it travels from the heater to your faucets.
- Check insulation regularly to ensure it remains intact and replace it when necessary.
Frequency | Maintenance Task | Best Practices | Estimated Costs |
Annually | Flushing the Tank | – Turn off power/gas. – Attach a hose to the drain valve. – Drain the tank completely. – Refill the tank and check for leaks. | $100 – $150 (if professionally done) |
Annually | Inspecting the Anode Rod | – Remove the anode rod and check for signs of corrosion. – Replace if less than 1/2 inch thick. | $50 – $150 (depending on water heater type) |
Annually | Checking the Thermostat | – Ensure the thermostat is set to 120°F. – Test for temperature consistency with a thermometer. | Free (if DIY) or $75 – $150 (professional check) |
Bi-Annually | Cleaning Heating Elements | – Remove mineral buildup. – Inspect for cracks or damage. – Replace if necessary. | $75 – $250 (for replacement) |
Bi-Annually | Inspecting for Leaks | – Check around the base for water pooling. – Look for signs of rust or corrosion. | Free (DIY) or $100 – $250 (if professional inspection required) |
Every 3-5 Years | Replacing the Sacrificial Anode Rod | – Replace if it has corroded beyond 1/2 inch. – Use magnesium or aluminum rods, especially for hard water areas. | $30 – $60 |
Every 5-10 Years | Complete Tank Inspection | – Have a professional inspect internal components, including tank corrosion. – Ensure structural integrity. | $100 – $300 |
Consequences of Water Heater Failure
Ignoring or neglecting water heater issues can lead to severe consequences, including a lack of hot water, strange noises, leaks, water discoloration, and unpleasant smells. These problems not only disrupt daily routines but also cause property damage and increase repair costs. Understanding these potential consequences can encourage timely maintenance and prompt action to avoid costly breakdowns.
No Hot Water
Experiencing no hot water can be one of the most inconvenient consequences of water heater failure. This issue is often caused by problems such as a faulty thermostat, damaged heating elements, or issues with the power or gas supply. Without hot water, basic tasks like showering, washing dishes, or doing laundry can become challenging.
To ensure you do not experience this disruption, here are a few preventive measures to consider:
- Check the thermostat to ensure it’s properly set and functioning.
- Inspect heating elements for wear or damage and replace them if necessary.
- Verify the power or gas supply to confirm that the heater is getting the necessary energy.
Strange Noises
If your water heater is making strange noises, such as rumbling or popping, this often points to a buildup of sediment or issues with the heating elements. As sediment accumulates at the bottom of the tank, it traps heat, causing the water to overheat and resulting in a noisy operation. These sounds are an early warning sign that the system is under stress and could lead to further damage if not addressed.
Here’s how you can prevent these disruptive sounds:
- Flush the tank regularly to remove sediment buildup and restore efficient heating.
- Inspect the heating elements for signs of corrosion or mineral buildup that could affect their function.
- Check the pressure relief valve to ensure it is operating correctly and relieving excess pressure.
Leaks Around the Tank
Leaks around the base of your water heater typically indicate corrosion, damage to the tank, or a failure of the internal components. This issue can lead to significant water damage in your home or business and may even cause the tank to fail if not dealt with promptly.
To prevent costly water damage and avoid tank failure, consider the following steps:
- Inspect the tank regularly for signs of rust or physical damage around the base.
- Replace the anode rod to help prevent internal corrosion and extend the tank’s lifespan.
- Check for pooling water around the tank, which could indicate an early leak.
Water Discoloration
If the water coming from your taps appears brown or reddish, it may be due to rust or sediment buildup inside the water heater tank. This discoloration is a clear indication that the tank is deteriorating, which can affect the quality of the water and lead to further damage if not addressed quickly.
To prevent water discoloration and maintain the quality of your water, follow these preventive measures:
- Replace the anode rod to prevent corrosion and the buildup of rust inside the tank.
- Flush the tank to remove sediment and rust that can affect the water quality.
- Install a filtration system to help prevent contaminants from entering the tank and affecting the water supply.
Unusual Smells
Foul odors, such as a sulfur-like smell, often arise from bacterial growth inside the water heater tank. These bacteria feed on the anode rod, producing a rotten egg odor that can make the water unpleasant to use. Ignoring this issue can lead to more severe contamination of the water, making it unsafe for use.
To eliminate this unpleasant odor and keep your water heater running smoothly, consider these actions:
- Replace the anode rod with one made from aluminum or magnesium to reduce the chances of bacterial growth.
- Flush the tank to remove bacteria and eliminate the odor.
- Increase the water temperature temporarily to kill any existing bacteria (up to 140°F for a short period).
Professional Help and When to Call a Technician
While regular maintenance can help, some water heater issues require professional attention. Problems like malfunctioning thermostats, faulty heating elements, or leaks often need specialized knowledge and tools to fix properly. Attempting DIY repairs can worsen the situation, leading to more damage and potential safety risks.
When facing more serious water heater problems, CPI Service offers expert water heater service to address and resolve these issues. Our skilled technicians are equipped to handle everything from diagnosing complex malfunctions to performing repairs and replacements. With CPI Service, you can trust that your water heater will be back to optimal performance, avoiding further damage and preventing costly water heater failure down the line.
If you're experiencing more serious water heater issues, don’t wait until it’s too late. Our expert technicians at CPI Service are ready to diagnose, repair, and replace your water heater, ensuring it runs efficiently and safely. Avoid costly repairs and further damage with professional service.
Or call us at (408) 549-8181 for immediate assistance.