Mechanical Hub recently caught up with the HammerHead Trenchless team at its St. Louis stop on the HammerHead Road Tour 2024. There, around 35 contractors took in this “lunch and learn”-type setting to get more acquainted with HammerHead product and service offerings. Right from the jump, there was a high priority on safety. “Safety is the foundation of everything we do,” says Jeff Urbanski, senior manager, training and marketing with HammerHead—and our trenchless professor for the day.

Of interest to the Mechanical Hub team were the three live demos—assisted by Thomas Davies, application specialist—which started with CIPP point repairs, which included the point repair process with a standard packer wrapped in fiberglass coated in resin inserted into a PVC DWV pipe.

Next, the group ventured outside to watch the lateral clay pipe bursting demo— initiated by Nate Hrabosky, regional sales manager and assisted by Davies—using HammerHead’s PortaBurst PB30 machine. The rugged PortaBurst system replaces 2 to 6″ lateral pipes with up to 30-tons of pulling force.

And saving perhaps the best for last, attendees get to see Hammerhead’s proprietary BlueLight LED CIPP lining system in full effect. The Bluelight LED CIPP lining system for laterals and small drain pipes is the most advanced light-curing system available. The LED light head up to five times faster than other methods. The specially formulated resin only cures under light in the “blue” wavelength, giving installers a significantly longer working time between liner wet-out and curing. Once installed, the automated curing system pulls the LED light head through the liner, curing the resin almost instantly—up to five times faster than other methods. Instead of waiting hours for the liner to cure, a 50-foot sewer line could be fully cured in under 10 minutes.

In fact, contractor friend Diego Lujan, president, Alphalete Plumbing Drain & Sewer Rehab (@alphalete_plumbing_drain_sewer), Colorado Springs, Colo., gives high marks for the Bluelight CIPP system. “At Alphalete Plumbing, we absolutely love using the HammerHead Translucent Blue Light CIPP Liner Cure Machine. It’s been a complete game-changer for us,” says Lujan.

“The speed and efficiency this machine delivers are unparalleled, making pipeline repairs easier, more reliable, and environmentally friendly. We can’t imagine using anything else—it’s forever our go-to for trenchless technology.”

The Road Tour is a great way to get up close and personal with HammerHead products. Nonetheless, the team is equally as excited to get on job sites across the country as well. “We love being on job sites, and we love solving problems,” says Urbanski.

Be sure to check out HammerHead on the road.

Remaining HammerHead Road Tour

• Raleigh, N.C. — July 16
• Des Moines, Iowa — July 23
• Salt Lake City — August 27
• Lake Mills, Wis. — More info coming soon!

Back in the day he was known as DJ Reggie Nell, and he could spin records with the best of ’em. A former DJ while working in the trades, Germaine Nelson, president, Capitol Plumbing & Heating, Bowie, Md., now is a full-service residential plumbing OG, specializing in water heaters, waste and venting for the surrounding DC area.

Nelson started his plumbing career back in high school, working with his uncle at a plumbing company during the summer. He also worked on pluming through his high school vocational program. “I went to school for a half day, then went to the job site the second half,” says Nelson. As soon as Nelson graduated, he started as an apprentice full time. “Seventeen years later, I own a plumbing company—started it from the ground up,” continues Nelson.

Early in his career, Nelson throws kudos the owner of 3D Plumbing, a small plumbing company for which Nelson worked. “The owner Dennis took me under his wing, and we still talk often. I consider him a mentor to this day,” says Nelson.

It wasn’t necessarily all smooth sailing. Throughout the journey, Nelson worked for a well-known company in the area as a service tech. They wanted to expand in a different part of the area, so he was tasked with building that area up, with the current contacts that he had.

Impressively, Nelson made more than $500,000 for that company within six months. “I asked for a raise, and the owner told me, ‘I can’t justify it but I can get you a new truck.’ At that moment, I knew it was time to go. I gave my two weeks’ notice,” says Nelson.

Nelson’s advice for anyone thinking about starting a company? “I would say just do it. You will have bumps and bruises along the way, but through dedication and consistency, you’ll succeed. Don’t give up on your vision.”

Challenges/Rewards

The most challenging aspects of the job, says Nelson, can be dealing with customers. “You have to learn how to put yourself in their position and understand what their needs area.”

Conversely, Nelson says it’s rewarding when you face a difficult challenge, but you overcome it with patience and skill. “I tell people all the time, plumbing is not hard, but finding a solution is the ultimate reward. You can sleep at night knowing you’re making a difference in society.”

And, according to Nelson, it starts early for those thinking of entering the trades, “Learn as much as you can because you will not know it all. Find your niche within the trade and foster that skill,” says Nelson.

Social Media

Nelson (@capitolmech) admits that social media has helped tremendously with making business connections and long-lasting friendships. “If it wasn’t for social media, I would not know about different trade shows, certain tools that makes the job easier and certain companies. I dedicate a lot of time to social media, more than I should, but it’s a lifestyle at this point,” says Nelson.

Through time and dedication on social media, Nelson has become an ambassador for various plumbing manufacturers. “Being an ambassador for different companies is special,” says Nelson. But he also says that it’s big task when a number of companies want to hire you as an ambassador because of your social media footprint. “Oatey, for instance, has really opened the door for a lot of these opportunities.”

And throughout this rise in popularity and visibility with social does Nelson consider himself a mentor to others? “I do consider myself a role model, not by choice, but through social media,” says Nelson. “I feel like I’ve been put into that position.”

When he’s not hard at work on the job or posting to IG, you’ll find Nelson spending time with family, attending his son’s baseball games, bowling, getting together with friends, or perhaps you’ll see him soaring in the sky fulfilling his bucket list of skydiving. Nevertheless, “It’s extremely important to make an effort to put work down and be intentional about taking care of your mental health, and being there for those who really depend on you,” says Nelson.

We have to admit, as a society most Americans have become lazier, or perhaps we’ve been conditioned to expect more, faster, with little effort as possible. Literally never having to leave the house for items delivered to your front door is just one shining example. But, hey, what’s not to like?

Yet, this begets a larger problem. Because homeowners can get something cheaper delivered to them in a relatively short amount of time lends itself to receiving, what I call, in some instances, junk. Eliminating the professional plumbing installer is a problem in and of itself, but do we really know where these items come from? Take, for example, products within our own plumbing and HVAC markets? Tools, fittings, pumps, plumbing fixtures, etc., are now “flooding” the streets with no real traceable origin, and no compliance or testing to boot.

The issue of counterfeit or noncompliant products on various e-commerce platforms is a real concern of the industry. A couple of weeks ago, I attended the Plumbing Industry Leadership Coalition (PILC) and this topic of conversation came up; it was presented to the attendees that on behalf PILC—of what I call all of the acronyms in the industry (ASPE, PHCC, IAPMO, PMI, etc.)—a letter was being drafted to legal counsel at Amazon, for example.

In fact, one of the charter members of PILC mentioned that they had purchased 25 showerheads off of an e-commerce site. These items claimed to be nearly 2.0 gallons per minute, and when measured at local testing facilities, approximately 20 out of the 25 fixtures were actually near a 6.0 gallon per minute measurement. That’s a huge discrepancy.

And that’s just it. Getting stuff delivered to your door—relatively quickly and cheaply—can be good for your endorphins, but it also can be a huge problem. There is no testing, certification or compliance happening from these “third-party vendors.” As mentioned above, it can cause harmful risks, and could potentially cause a water sustainability problem. Again, therein lies the problem.

Realistically, what can be done about it? PILC suggests a number of action items, which include implementing a stricter verification process, ensuring that all legal and safety standards by either requiring certification or at least to verify that certification claims are true, and provide better transparency: provide clear information about the compliance and certification of products, making it easier for consumers to make informed decisions.

… what is the level of scale in your water? Hard to say, I’d imagine. But, over time, believe me, you’ll know. Scale, also known as limescale, refers to mineral buildup—primarily magnesium and calcium—that creates a white, chalky-like substance that can accumulate on the plumbing system’s internal components, including water heaters, pipes, and fixtures, says Randall Oshiro, Lead Engineer, Noritz America.

In other words, “Common in household water, especially in areas with hard water, scale is essentially the crusty stuff you sometimes see on old pipes or the heating element of an old kettle,” says Ben Tate, National Sales Manager—Water Treatment, Navien, Inc. “When water is heated, these minerals crystallize and stick to surfaces such as the interiors of pipes, boilers, and heaters, forming a hard, insulating layer. It’s a natural process, but not exactly a welcome one, as it hampers the efficiency of any appliance it settles in.”

Scale’s Geography

Scale’s prevalence comes down to the geological makeup of the land through which your water travels. Water is a universal solvent, and as it moves through soil and rock, it picks up minerals like calcium and magnesium. In areas rich in limestone and other calcareous rocks, which are composed mainly of calcium carbonate, water tends to carry a higher load of these minerals. Consequently, regions with such geological features—think of areas like Texas and Florida—often struggle more with hard water and, by extension, scale.

Calcium and magnesium are naturally occurring minerals, says Oshiro. Depending on where the water is drawn from, water flowing through ground sources that contain high concentrations of these minerals will absorb some of the minerals. For example, water drawn from an aquifer with a high concentration of limestone will inevitably have a high concentration of lime (calcium). Like the previous example, areas where water is drawn from underground are often where the highest concentration of hard water exists.

A Water Heater’s Nemesis

Yet the “damage” scale can bring can’t be overstated, says Dan Giosia, Assistant Product Manager, Bradford White Corporation, “The accumulation of scale in a water heating system diminishes the overall performance, efficiency, and lifespan of the water heater unless preventative maintenance measures are implemented.”

Scale poses a triple threat to water heating systems, says Tate. First, it’s an insulator. In a domain where efficient heat transfer is key, scale is a formidable barrier that keeps heat from doing its job effectively, which can drive up energy costs as your system struggles to keep up. Second, scale buildup increases the pressure in water lines and heating chambers, which can lead to leaks or mechanical failures. Lastly, the more energy and repairs a system requires, the more its lifespan diminishes. That’s why preventing scale isn’t just about maintaining water flow; it’s about saving money and extending the life of your equipment.

According to Oshiro, the primary danger of this scale formation is that it can accumulate inside the water heater (on the heat exchanger of tankless water heaters, along electrical heating elements, or along the internal flue of gas storage water heaters). This scale formation acts as an insulator in large amounts, preventing the proper heat exchange between the water and the heating source. “When this happens, the temperature will increase—as heat is not being drawn away at the designed rate—leading to increased thermal stress and decreased longevity of the internal components. Additionally, this buildup can reduce the surface area of piping, which can reduce the flow performance of the fixtures as well,” says Oshiro.

Tankless Magnified

Scale impacts both tank-type and tankless water heaters, though it manifests differently in each system, says Tate. In tank-type heaters, scale settles at the bottom of the tank, reducing heat transfer efficiency and leading to increased energy consumption and potential corrosion. Over time, this can significantly shorten the lifespan of the heater. Conversely, tankless models, which heat water directly, experience scale buildup directly on their heat exchangers. This can decrease heating efficiency and disrupt water flow, though it does not necessarily indicate a greater susceptibility to scale than tank-type heaters.

Regardless of the system type, the key to mitigating scale effects lies in regular maintenance. Both tank-type and tankless water heaters benefit from routine descaling and the proactive use of water treatment solutions like water softeners or scale inhibitors. Properly maintained, both systems can handle scale effectively, ensuring efficient operation and extending the lifespan of the heater. Thus, neither system is disadvantaged by scale when properly cared for, allowing users to choose based on their specific needs and preferences.

The reality is the mechanism/issue is about the same for both types of technology. “However, it will present itself much sooner/more apparently with a tankless type water heater than a tank-type water heater. The reason for this is basically that the pipes are smaller. Imagine a ¾” pipe and 24” round storage vessel. The smaller pipe, with a ¼” of scale buildup, loses significantly more of its surface area in comparison. This means that issues like reduced flow will become more apparent sooner,” says Oshiro.

However, it should be noted, continues Oshiro, that this same amount of scale will have the same actual effect on the systems (reduced efficiency, higher thermal stress). As a result, a tankless water heater may show signs of decreased performance sooner; however, this also allows the customer to preemptively conduct maintenance to ensure that the product will last many times longer than a storage tank-type water heater.

The storage tank-type water heater often continues to build up this scale over time, resulting in lower efficiencies (meaning higher operating costs) and eventual failure sooner. This scale formation is one of the primary mechanisms by which water heaters will fail. ¹

According to Bradford White’s Giosia, scale does pose a greater issue for tankless water heaters compared to tank-type water heaters due to their compact heat exchanger design. With a limited surface area and brief heating period, tankless heaters must rapidly elevate water temperatures, requiring high temperatures within the heat exchanger. As a result, scale tends to accumulate on this surface. If scale buildup becomes excessive, it can restrict water flow through the heat exchanger to the point of causing component or unit failure so it’s important for homeowners to contact their plumbing professional for regular maintenance.

In comparison to gas tank-type water heaters, electric tank-type heaters are generally more susceptible to scale buildup. This is primarily due to the very hot surfaces of electric heating elements, which have a small area and are prone to accumulating limescale within the tank. However, the impact of scale buildup is limited by the fact that electric heating elements are relatively inexpensive to replace, especially when compared to the cost of replacing a tankless gas heat exchanger or complete unit.

Gas tank-type water heaters may vary in susceptibility to scale buildup depending on their design. Units with a burner located outside the tank are typically less affected by scale compared to those with an internal heat exchanger where scale can accumulate.

Action Plan

What can contractors/homeowners do to “combat” scale? “The first step is to know your water supply,” says Oshiro. “Almost every municipal water supply company will annually publish a water quality report that will include data about the hardness of your water supply. This rating will often be rated on a scale of grains per gallon (gpg), parts per million (ppm), or milligrams per liter (mg/L). These ratings tell the density of mineral hardness (calcium) present in the water supply. The USGS^[1] has a relative hardness indicator, where 61-120 mg/L (3.6-6 gpg) would be considered somewhat hard water.”

The best way to reduce scale is to treat the cause. This means using water treatment devices to prevent the calcium from building up in your water heater and piping. However, this isn’t always possible, so maintenance can be conducted by a descale flush: running a deliming agent (ex., vinegar or a specialized deliming agent) solution through piping the water heater to neutralize the calcium. As calcium is a basic material (pH >7), the acidic deliming agent will neutralize the calcium and remove buildup.

It’s also essential to adhere to the manufacturer’s recommendations for preventative maintenance, including specific procedures and frequency, for their product, advises Giosia.

Regular descaling of the water heater is often recommended to minimize scale buildup on the heat exchanger of a tankless water heater. The frequency of preventative maintenance typically depends on the characteristics of the water supply in your area, such as whether it is heating hard or soft water.

Installing a water softener can help reduce the hardness of the incoming water into both tankless and tank-type water heaters. However, it’s important to consult with a plumbing professional to ensure compatibility and to follow their recommendations.

Navien’s Tate says contractors and homeowners in these regions should adopt a proactive approach to water treatment. Installing a water softener is one effective strategy; it replaces hardness ions like calcium and magnesium with sodium or potassium, preventing them from forming scale. Additionally, I’d recommend considering scale prevention systems, which are designed to transform hardness minerals into harmless crystals that won’t stick to surfaces. Regular maintenance checks are also vital—they help ensure that any potential scale buildup is managed before it becomes a serious issue.

If you know that your water source is hard water, Oshiro suggests that you can take action to alleviate the risks.

• Develop a routine maintenance plan: This can be done by “descaling,” or flushing, your water heater regularly, depending on usage and quality. Asking your water heater manufacturer or installer for recommendations on frequency is a great first step.
• Treat the water: There are ways to eliminate (sequester or remove) hard-water minerals from the water source. These include items like water softeners, which use an ion-exchange process to physically remove free calcium from the water, or products that use a polyphosphate media to sequester the calcium to prevent it from coming out of the solution when heated.

Technology Tips

Is there newer technology that could make the equipment more scale-resistant? “Indeed,” says Tate. “One of the latest advancements in this area is Template Assisted Crystallization (TAC), which is a highly effective technology for preventing scale without the use of chemicals or salt. TAC systems work by transforming the calcium and magnesium minerals in hard water into stable, harmless crystal particles. These particles then flow through the system without sticking to surfaces, effectively preventing scale buildup. This technology is particularly useful for protecting high-efficiency tankless water heaters from scale, ensuring they operate at optimal efficiency while extending their lifespan.”

To some degree, says Oshiro, the selection of materials, design of the heat transfer surface, and the temperature in which the system operates, all have roles to play in controlling the amount of scale formation.

• Materials with less surface roughness provide less chance for scale particles to attach.
• Systems with lower temperature rises can also slightly reduce the formation rate of scale.

There is constant research into reducing the harmful effects of scale formation in water heating products, but at its core, it is a challenging situation to avoid entirely.

According to Giosia, some tankless water heater models incorporate technology aimed at enhancing scale resistance, such as scale reduction technology and replacement filtration cartridges. Moreover, water softeners can serve a similar purpose in mitigating scale buildup.

However, despite these advancements, maintenance remains essential for all tankless water heaters to prevent excessive scale accumulation. Regular upkeep is necessary to ensure optimal performance and longevity of the unit.

In conclusion, the timeline for significant damage can vary widely depending on the water’s hardness and the frequency of system maintenance. In regions with very hard water and minimal preventive measures, says Tate, significant scale buildup can occur within just a few months, leading to efficiency losses and potential system failures. Conversely, with proper management and regular maintenance, scale-related damage can often be staved off for years, preserving the efficiency and extending the life of the system.

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https://www.usgs.gov/special-topics/water-science-school/science/hardness-water#:~:text=Measures%20of%20water%20hardness&text=General%20guidelines%20for%20classification%20of,mg%2FL%20as%20very%20hard