Water Heater Installation Guide

Sizing calculations, venting requirements, connections, expansion tanks, and safety devices

Understanding Tank-Style Water Heaters

A tank-style water heater stores and heats a reservoir of water (typically 30-80 gallons) using gas burners or electric heating elements. When hot water is used, cold water enters the tank to be heated for the next use.

These systems are the most common residential water heating solution, offering reliable performance and lower upfront costs compared to tankless systems. Proper installation is critical for safety, efficiency, and longevity.

Key Components: Tank-style water heaters include a storage tank with insulation, heating mechanism (gas burner or electric elements), temperature & pressure relief valve, dip tube for cold water, and flue pipe (gas units only) for exhaust venting.

Sizing Your Water Heater

Sizing by Household Occupants

Number of People	Gas Water Heater	Electric Water Heater	Notes
1-2 people	30-40 gallons	30-40 gallons	Adequate for apartments or small homes
2-3 people	40-50 gallons	40-50 gallons	Standard family size
3-4 people	40-50 gallons	50-65 gallons	Gas recovers faster than electric
5+ people	50-75 gallons	65-80 gallons	Consider multiple units or tankless

First Hour Rating (FHR)

The First Hour Rating indicates how many gallons of hot water the heater can supply in one hour during peak demand. This is often more important than tank capacity.

Calculating Your Peak Hour Demand

Add up gallons used during your busiest hour:

Shower: 10-20 gallons
Bath: 15-20 gallons
Dishwasher: 6-10 gallons
Washing machine: 7-12 gallons
Kitchen sink: 3-5 gallons
Bathroom sink: 2-4 gallons

Choose a water heater with an FHR that meets or exceeds your calculated peak demand. Look for the FHR on the EnergyGuide label.

Gas vs Electric Recovery: Gas water heaters recover (reheat) approximately 40-50 gallons per hour, while electric units recover only 12-20 gallons per hour. This allows gas units to have smaller tanks for the same household size.

Gas vs Electric Requirements

Gas Water Heater Requirements

• Gas supply line: 1/2" or 3/4" black iron pipe or CSST flexible gas line
• BTU input: Typically 30,000-50,000 BTU/hr for residential units
• Venting: Requires proper flue pipe to exhaust combustion gases (see venting section)
• Combustion air: Adequate air supply for burner (1 sq in per 1,000 BTU or use direct vent)
• Gas shutoff valve: Required within 6 feet of appliance
• Drip leg: Sediment trap required on gas line
• Clearances: 6" from combustibles (check manufacturer specs)

Electric Water Heater Requirements

• Dedicated circuit: Required (not shared with other appliances)
• Voltage: 240V for most residential units
• Amperage: 20-30 amps typical (check rating plate)
• Wire size: 10 AWG for 30A circuit, 12 AWG for 20A circuit
• Breaker: 30A double-pole breaker most common
• Conduit: May be required by local code (flexible or rigid)
• No venting required: Major advantage over gas units
• Junction box: All wire connections must be in approved box

Factor	Gas	Electric
Installation Cost	Higher (venting complexity)	Lower (simpler)
Operating Cost	Lower (cheaper fuel)	Higher (electric rates)
Recovery Speed	Faster (40-50 gal/hr)	Slower (12-20 gal/hr)
Energy Efficiency	60-70% (venting losses)	90-95% (no venting)
Lifespan	8-12 years	10-15 years

Gas Water Heater Venting Types & Clearances

Venting System Types

Venting Type	Description	Requirements	Best For
Atmospheric Vent	Natural draft through vertical flue pipe	Single-wall or Type B vent pipe, vertical run with minimal horizontal	Traditional installations with chimney or roof vent
Direct Vent	Sealed combustion, draws air from outside and vents outside	Concentric or separate PVC/metal pipes through exterior wall	Interior installations, tight homes, no chimney available
Power Vent	Electric blower forces exhaust out	PVC or special vent pipe, requires 120V power, can run horizontally	When vertical venting is impractical, basement installations
Condensing	High-efficiency with secondary heat exchanger	PVC vent pipe, condensate drain required, 90%+ efficiency	Maximum efficiency, similar to tankless venting

Atmospheric Vent Specifications

Single-wall pipe: 6" clearance from combustibles
Type B (double-wall) pipe: 1" clearance from combustibles
Minimum diameter: Typically 3" or 4" (match heater draft hood)
Slope: 1/4" rise per foot minimum for horizontal runs
Horizontal run limit: Typically 75% of vertical height
Draft hood clearance: 6" minimum from combustibles
Termination: Must extend above roof per code (typically 2 feet above any part within 10 feet)

Common Venting Mistakes

❌ Undersized vent pipe: Causes backdrafting and carbon monoxide hazards
❌ Too many elbows: Each 90° elbow reduces draft significantly
❌ Negative slope: Can trap condensation and cause corrosion
❌ Connecting to wrong chimney: Must use separate flue or properly sized common vent
❌ Inadequate combustion air: Causes poor performance and safety issues
❌ Using wrong pipe material: Never use PVC for atmospheric vents

Carbon Monoxide Warning: Improper venting is deadly. All gas water heaters must be properly vented to the exterior. Never use unvented gas appliances in living spaces. Install CO detectors on every level of your home.

Water Line Connections

Required Connections

Cold water inlet: Connects to home's cold water supply (typically 3/4" pipe)
Hot water outlet: Delivers heated water to fixtures (typically 3/4" pipe)
Shutoff valve: Required on cold water inlet within 5 feet of tank
Drain valve: Pre-installed at bottom of tank for flushing sediment
T&P valve discharge: Required pipe to safe location (see safety section)

Piping Materials

Material	Uses	Pros	Cons
Copper (Type L)	Hot and cold supply lines	Durable, code-approved everywhere	Expensive, requires soldering or crimping
PEX	Hot and cold supply lines	Easy to work with, flexible, freeze-resistant	Not allowed in some jurisdictions, UV-sensitive
CPVC	Hot and cold supply lines	Low cost, easy glued connections	Can become brittle, lower temperature rating
Flexible Connectors	Final connections to tank	Accommodates movement, easy installation	Shorter lifespan, may not be code-approved

Connection Best Practices

Use dielectric unions to connect dissimilar metals
Install brass ball valve (not gate valve) for main shutoff
Support pipes properly to prevent stress on connections
Use thread sealant or Teflon tape on threaded connections (not both)
Leave 6" clearance around tank for future maintenance
Install shutoff valves on both hot and cold lines for easy replacement

Expansion Tank Requirements

An expansion tank (also called a thermal expansion tank) is a small tank installed on the cold water supply line that absorbs excess pressure caused by water expansion when heated.

When Required: Expansion tanks are required by code in most areas when a check valve, pressure-reducing valve, or backflow preventer is installed on the main water supply. These devices create a "closed system" that prevents expanded water from flowing back into the street main.

Sizing an Expansion Tank

Water Heater Size	Expansion Tank Size	Notes
30-40 gallons	2 gallon tank	Typical small household
40-60 gallons	2-5 gallon tank	Most common residential size
60-80 gallons	5 gallon tank	Large households
80-100+ gallons	7.5-10 gallon tank	Consult expansion tank sizing calculator

Installation Guidelines

Install on cold water supply line before water heater shutoff valve
Mount vertically with air chamber on top (preferred orientation)
Use Teflon tape on threaded connection
Pre-charge air pressure to match house water pressure (typically 40-60 PSI)
Support tank weight independently (don't stress pipes)
Locate where accessible for future air pressure checks and replacement

Signs You Need an Expansion Tank

T&P valve drips or releases water frequently
Pipes make banging noises (water hammer)
Fixtures have high water pressure fluctuations
Water heater tank develops leaks prematurely
Your municipality requires check valves (closed system)

Temperature & Pressure Relief Valve (T&P Valve)

The T&P valve is the most critical safety device on a water heater. It automatically releases water if temperature exceeds 210°F or pressure exceeds 150 PSI, preventing tank explosion.

Critical Safety Device: NEVER cap, plug, or remove the T&P valve. NEVER restrict the discharge pipe. A failed or blocked T&P valve can result in catastrophic tank explosion causing severe injury or death.

T&P Valve Requirements

Rating: Must match or exceed tank pressure rating (typically 150 PSI)
Location: Installed in top or upper side of tank
BTU rating: Must exceed heater BTU input (gas units)
Testing: Test valve annually by lifting lever briefly
Replacement: Replace every 5 years or if it fails to seal after testing

Discharge Pipe Requirements

Material: Copper, CPVC (where allowed), or galvanized steel
Size: Same diameter as valve outlet (typically 3/4")
Length: As short as practical, no more than 30 feet total
Slope: Drain by gravity (downward slope, no traps)
Termination: Within 6" of floor, into drain, or exterior (splash block required)
No valves: NEVER install a valve on the discharge pipe
No threads at end: Pipe must terminate in a plain open end
Visible termination: Must discharge to a visible location
Maximum 4 elbows: Minimize flow restriction

Common Termination Locations

Floor drain in mechanical room or garage
Drain pan beneath water heater (if properly drained)
Exterior wall, terminating 6-24" above grade with splash block
Utility sink (indirect connection - air gap required, not directly threaded)
Outside through wall in area where hot water discharge won't cause damage

Earthquake Strapping Requirements

Seismic strapping (earthquake strapping) secures the water heater to wall studs or masonry to prevent tipping during earthquakes. Required in seismically active areas, but good practice everywhere.

Required in: California, Alaska, Hawaii, Nevada, Utah, Washington, Oregon, and many other jurisdictions. Check your local building codes for specific requirements.

Strapping Specifications

Two straps required: One at upper 1/3 of tank, one at lower 1/3
Material: 22-26 gauge metal strapping or approved seismic restraint kit
Width: Minimum 1" wide strap
Fasteners: 1/4" lag screws minimum (into studs) or appropriate masonry anchors
Penetration: Lag screws must penetrate studs at least 1-1/2"
Wrap: Strap must wrap at least 3/4 around circumference of tank
Tension: Straps should be snug but not deforming tank
Clearance: Straps should not obstruct T&P valve, controls, or access panels

Installation Steps

Locate wall studs (or use masonry anchors for concrete walls)
Position upper strap in upper third of tank (avoid obstructions)
Wrap strap around tank, pull tight, and mark holes on wall
Install 1/4" x 3" lag screws into studs (pre-drill to prevent splitting)
Repeat for lower strap in lower third of tank (above burner compartment)
Tighten straps until snug (don't over-tighten)
Verify tank cannot tip more than a few inches in any direction

Pre-Made Seismic Strap Kits

Several manufacturers offer complete earthquake strap kits that include:

Metal strapping pre-cut to appropriate lengths
Lag screws and washers
Corner brackets or pre-formed straps
Installation instructions specific to tank size

These kits simplify installation and ensure compliance with seismic codes.

Step-by-Step Installation Process

Turn Off Utilities and Drain Old Unit

Turn off gas/electricity and water supply. Attach garden hose to drain valve and empty tank completely. Disconnect supply lines and remove old unit.

Position New Water Heater

Place new heater in location with proper clearances (6" from combustibles for gas). Use appliance dolly and ensure level placement. Install drain pan if required.

Install T&P Valve and Discharge Pipe

Apply Teflon tape and install T&P valve if not pre-installed. Attach discharge pipe running to proper termination point (floor drain or exterior). Ensure downward slope.

Connect Water Lines

Install dielectric unions on both hot and cold connections. Connect water supply lines using appropriate pipe material. Install shutoff valve on cold line. Install expansion tank if required.

Connect Gas or Electrical Supply

Gas: Connect gas line with drip leg, install shutoff valve, perform leak test with soapy water. Electric: Connect wiring in junction box, verify 240V at breaker panel.

Install Venting (Gas Units Only)

Connect draft hood to flue pipe using appropriate vent material. Ensure proper slope and clearances. Seal joints with sheet metal screws. Verify draft with smoke test.

Fill Tank and Check for Leaks

Open cold water shutoff and fill tank (leave hot water faucet open to purge air). Check all connections for leaks. Verify no drips from T&P valve.

Light Pilot or Turn On Power

Gas: Follow lighting instructions on tank, set thermostat to 120°F. Electric: Turn on circuit breaker, verify heating elements activate.

Install Earthquake Strapping

Attach upper and lower straps around tank secured to wall studs with lag screws. Verify tank is secure and cannot tip.

Test Operation and Call for Inspection

Wait for tank to heat (2-3 hours), verify hot water at fixtures. Test T&P valve. Schedule building inspection if required. Label electrical disconnect/gas shutoff.

Permit and Inspection Requirements

When Permits Are Required

Most jurisdictions require permits for water heater replacement or installation, especially when involving gas, electrical, or plumbing modifications.

Installing a new water heater in a new location
Replacing an existing water heater (like-for-like)
Switching fuel types (gas to electric or vice versa)
Upgrading capacity or changing configuration
Installing tankless or on-demand systems

Typical Inspection Points

Proper venting installation and clearances (gas units)
T&P valve and discharge pipe compliance
Gas line sizing and connections with leak test
Electrical circuit sizing, grounding, and GFCI protection (if required)
Expansion tank installation (closed systems)
Seismic strapping in earthquake-prone areas
Drain pan and proper drainage (if required)
Clearances from combustibles
Carbon monoxide detectors near gas appliances

Homeowner vs Licensed Contractor: Some jurisdictions allow homeowners to install their own water heaters with a permit. Others require licensed plumbers or electricians. Always check local requirements before starting work.

Tools and Materials Needed

Tools

Adjustable wrenches (10" and 14")
Pipe wrenches (if working with black iron)
Tubing cutter or hacksaw
Propane torch (for copper soldering)
Screwdriver set
Drill with bits
Level
Tape measure
Appliance dolly
Garden hose (for draining)
Bucket and towels
Voltmeter (electric units)

Materials

Water heater (sized appropriately)
T&P valve (if not included)
Discharge pipe (copper or CPVC)
Dielectric unions (2)
Flex connectors or copper/PEX pipe
Shutoff valve (cold line)
Expansion tank (if required)
Gas line materials or electrical wire
Vent pipe (gas units)
Earthquake straps and lag screws
Teflon tape or pipe dope
Solder and flux (copper)
Drain pan (if required)

Safety and Code Considerations

Gas Leak Hazard: Natural gas and propane are explosive. Always perform leak tests with soapy water on all gas connections. If you smell gas, shut off the gas supply immediately, evacuate, and call your gas utility or fire department.

Carbon Monoxide Poisoning: Improper venting or combustion air can produce deadly carbon monoxide. Install CO detectors on every level. Never operate a gas water heater without proper venting to the outside.

Electrical Shock: Water heaters use 240V power which can be lethal. Turn off power at the breaker and verify with a voltmeter before working on electrical connections. Never work on live circuits.

Scalding Water: Set thermostat to 120°F maximum to prevent scalding injuries, especially for households with children or elderly. Water above 140°F can cause severe burns in seconds.

Tank Explosion: Never cap or plug the T&P valve or discharge pipe. A blocked relief valve can cause catastrophic tank explosion. Always maintain proper pressure relief.

Note: Water heater installation involves gas, electrical, and plumbing work that must comply with local building codes. Many jurisdictions require permits and inspections. Consider hiring a licensed professional if you're not experienced with these systems.

Quick Reference Summary

Essential Checklist

Size properly: 40-50 gal for 2-4 people
T&P valve: Must discharge to safe location
Expansion tank: Required in closed systems
Venting: Proper sizing and slope (gas units)
Strapping: Two straps in seismic areas
Shutoff valve: On cold water line

Key Safety Points

Always obtain permits and schedule inspections
Test all gas connections for leaks
Verify proper venting before operation
Set thermostat to 120°F max
Install CO detectors near gas appliances
Never obstruct T&P valve discharge

Disclaimer: This guide provides general information about water heater installation. Local building codes, manufacturer specifications, and fuel types may require different approaches. Installation of gas and electrical appliances can be dangerous and may require licensed professionals. Always consult local codes, obtain required permits, and consider hiring a licensed plumber or electrician for proper installation.