The worst install we ever ripped out (and the boiler with a Rubbermaid tote for a condensate pump)
I have seen some rough work over 46 years. This combination boiler is the one I still tell people about, and it is a good lesson in why the company you pick matters more than anything.
The worst install we ever ripped out was a combination boiler where the potable water service valves were cross-connected to the hydronic heating side, which left no temperature safety on the drinking water and created a genuinely dangerous setup. On top of that, the installer used an appliance connector where it did not belong, skipped the dirt leg, and when the condensate pump failed they replaced it with a green Rubbermaid tote and a sump pump. We tore it all out and rebuilt it into one of the most beautiful boiler installs we have ever done.
How we ended up across the street
We were doing a job for a really good customer, running a building drain and a rain leader, so we were on site for a while. The whole time, there was a competitor working the house across the street, and they were there for about two weeks. On an HVAC change-out for a renovation, not even new construction, two weeks is ridiculous. Eventually the homeowner across the street walked over and talked to my dad, who was doing a site visit.
Here is the part that stuck with me. This was a very reputable company. My dad used to speak highly of them back in the day. But they had gotten bought out by a private equity group, and whatever was going on over there, they screwed up this install so badly they could not even figure out how to fix it. So we got brought in, ripped out all the equipment, and started fresh. Two or three days later it was up and running. No big deal for our team.
The combination boiler that scared me
The one I really want to walk you through is a job we did more recently. We were ripping out a combination boiler, which is honestly one of the things we do better than anybody on this planet. A combination boiler heats your home and makes your domestic hot water out of one appliance, so the piping has to be exactly right.
When we opened it up, here is what we found:
- The service valves were cross-connected. The valves for the water heating side were piped into the hydronic heating side of the appliance. Totally incorrect, and totally unsafe. The temperature and pressure relief on potable drinking water and on hydronic heating are very different, so this was an immediate, glaring red flag.
- No temperature safety on the drinking water. Because of that cross-connect, there was no temperature safety device protecting the potable water side at all. That is a dangerous situation, not a cosmetic one.
- The wrong gas connector. They used an appliance connector, which as a company we only ever put on movable appliances. That is not what belongs on a fixed boiler.
- No dirt leg. A dirt leg catches moisture and debris before it reaches the burners. Skip it and you let junk into the burners, and eventually the unit stops working right.
The Rubbermaid tote and the sump pump
And that was not even the best part. The whole job looked like a mess, like amateur hour did it. But the real kicker was the condensate. A high-efficiency boiler makes acidic condensate water that has to be pumped away, and the little condensate pump on this thing had gone bad. So instead of buying a new condensate pump, this company took a big green Rubbermaid container, slid it under the boiler, dropped a sump pump in it, and piped that into the condensate.
I have been doing this since 2006 and I have never seen anything so jerry-rigged in my life. That is not a repair. That is a hazard with a lid on it.
Why this is really a story about picking a company
Here is the thing I want every Pittsburgh homeowner to take from this. The reputable name on the truck did not protect that customer. The codes and inspectors did not catch it either. The industry we work in is closer to the wild west than most people realize, and so much of what you actually get comes down to which company you let in the door. That is exactly why we are obsessive about our Google and Better Business Bureau reviews, because those have been the most honest way to judge a company.
When we were done with this one, it turned into one of the most beautiful boiler installs we have ever done. We absolutely crushed it for that customer. If it looks good, it is good, and that is the standard, every time. If you want to understand what actually goes into doing one right, start with how to pick a boiler for a Pittsburgh home.
The quick version
- We tore out a combination boiler where the drinking-water valves were cross-connected to the heating side, leaving no temperature safety on the potable water.
- The same job had the wrong gas connector, no dirt leg, and a sump pump in a Rubbermaid tote instead of a real condensate pump.
- A reputable name on the truck did not protect the customer. After a private equity buyout, the original company could not even fix its own work.
- Codes and inspectors do not catch most of this. The company you pick is the real safeguard.
- Check Google reviews and the Better Business Bureau before you let anyone work on your boiler.
I have never seen anything so jerry-rigged in my life, a sump pump in a Rubbermaid tote doing the job of a condensate pump, on a boiler that was unsafe from the first valve.
That job is why I tell people the company you pick matters more than the brand on the box. We ripped it out and made it beautiful, because that is the only standard we have.
David WahlCEO & Master Plumber, Wahl Family
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Call 1-855-GET-WAHLFrequently asked questions
Why is cross-connecting the potable and hydronic sides of a combi boiler dangerous?
Because the temperature and pressure safety requirements for drinking water and for hydronic heating water are different. When the valves are cross-connected, the potable water can be left with no proper temperature safety device, which is a genuine hazard, not a cosmetic problem. A combination boiler has to be piped exactly to the manufacturer’s design.
What is a dirt leg and why does a boiler need one?
A dirt leg is a short section of pipe that catches moisture and debris in the gas line before it reaches the burners. Skipping it lets dirt and condensation into the burners over time, which keeps the unit from working properly. It is a standard detail that good installers never leave out.
Is it a red flag if an HVAC change-out takes two weeks?
On a renovation that is not new construction, yes, it usually is. A competent crew can replace and start up most residential systems in a few days. A job that drags on for two weeks often means the installer is in over their head, which is exactly what we found across the street from one of our customers.
How do I know if my own boiler was installed correctly?
Have a licensed heating and plumbing contractor inspect the near-boiler piping, the safety devices, the gas connection, and the condensate setup. We do this all the time and can tell you fast whether your system is safe and built to standard. Read how to pick a boiler for what good looks like.
Does a well-known company name guarantee good work?
No. We tore out a bad install done by a once-reputable company that had been bought by private equity and could not even fix its own mistakes. The brand on the truck is not a guarantee. Your best protection is checking honest reviews on Google and the Better Business Bureau before you hire.
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