What's causing this crust on the boiler?
I had this new boiler installed January 2025 by New England Steamworks, and unfortunately I'm now past their 1 year warranty period. But today I checked my boiler and there's a ton of crust near the water heating coil.
What caused this? And is this something I can fix DIY?
Comments
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Electrolysis and/or small leak. I wouldn't touch it until you are ready to repair it properly. And you definitely want to fix it before it rusts the bolt on the coil, although it looks like it has the kind of coil with pass thru bolts.
You can try shutting off the main water supply and hitting it with a wire brush. But again if it starts to leak, you might be in for a bigger job.
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Oof. Is this leak something to call the professionals in for?
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a very small leak
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That is caused by a leak, probably been leaking for a while, maybe since new. You probably should look at (inspect) your boiler more than once every 14 Months.
DIY repair ? Maybe, it depends on your skills.
National - U.S. Gas Boiler 45+ Years Old
Steam 300 SQ. FT. - EDR 347
One Pipe System
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I had it serviced last June, when the tech noticed it but said it was minor/not a big deal. I've swung by the boiler and had a water leak monitor nearby that never went off but honestly just never looked that closely at it until today when I went to adjust the aquastat.
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" minor/not a big deal "
Well… Now you need to pay for the repair that could have been repaired under warranty. I guess it depends on your opinion of a "big deal".
Maybe the Tech that seemed to imply it should be ignored will repair it for free.
National - U.S. Gas Boiler 45+ Years Old
Steam 300 SQ. FT. - EDR 347
One Pipe System
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So why are you adjusting the Aquastat?
Anyway, that is just a small leak, likely because the pipe sealant was insufficient, the fitting was not tightened enough, or the fitting was soldered after it was installed on the coil. I would recommend getting a wire brush, cleaning it down to bare metal, and then spray painting it with some Rust-Oleum. Black would be my color choice. Then keep an eye on it.
Another thing that no one looks at is the bolts that seal the coil to the gasket and the boiler. After about 500 hours of operation, they should be snugged up. You may find that even though they were tightened at the factory, after 14 months of use those bolts are now only hand-tight. Those gaskets shrink after they are heated for several months. that is why they are not as tight at they were when the boiler was new.
In another 6 months check them again. That should be the last time you will need to tighten them. then the coil gasket will look new for years after that.
See how this coil cover plate that has no coil, is rusting away from the coil plate gasket? Tighten those bolts!
Edward Young Retired
After you make that expensive repair and you still have the same problem, What will you check next?
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This should come under the boiler manufacturer's warranty. Call @New England SteamWorks , they should be able to handle it for you.
All Steamed Up, Inc.
Towson, MD, USA
Steam, Vapor & Hot-Water Heating Specialists
Oil & Gas Burner Service
Consulting0 -
that’s not a manufactures defect.
those fittings are field installed.1 -
if the coil bolts weren't installed with antiseize they probably should be taken out one at a time and have some antiseize added in addition to the retorquing to take up the gasket creeping.
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did you contact @New England SteamWorks ? they don't have to cover it under warranty buty they might if you aks nice.
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I filed a rather sad trombone ticket with them and it looks like NE Steamworks is willing to work with me on this despite it being out of warranty! I see now why they have their reputation. They'd have been within their rights to ignore me and my lack of observational skills haha!
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And thank you Ed for the helpful tips. I'll definitely keep a closer eye on these going forward.
And maybe a dumb thing but I adjusted the aquastat down because the boiler was constantly firing itself up just for water heating even when heat isn't needed at the previous temp (like 160 I think), and with oil prices the way they are, I'm being a bit more conscientious about how often it's running. At the new temp around 120-130 I don't hear it constantly coming on anymore and the water temps still feel fine.
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If you'd opted for the indirect over the tankless, this travesty could've been avoided. Maybe.
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Ryan at @New England SteamWorks is one of the best. We expected no less.
All Steamed Up, Inc.
Towson, MD, USA
Steam, Vapor & Hot-Water Heating Specialists
Oil & Gas Burner Service
Consulting
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Or just a water heater, definitely
NJ Steam Homeowner.
See my sight glass boiler videos: https://bit.ly/3sZW1el0 -
Reposted with a photo: I asked Daniel Friedman from InspectApedia.com for permission to use a copyrighted photo from his site and was waiting for a reply. Nice guy.
So here is the full post again, with the photo that explains the gasket problem visually.
Original comment: Anyway, that is just a small leak, likely because the pipe sealant was insufficient,he fitting was not tightened enough, or the fitting was soldered after it was installed on the coil. I would recommend getting a wire brush, cleaning it down to bare metal, and then spray painting it with some Rust-Oleum. Black would be my color choice. Then keep an eye on it.
Another thing that no one looks at is the bolts that seal the coil to the gasket and the boiler. After about 500 hours of operation, they should be snugged up. You may find that even though they were tightened at the factory, after 14 months of use those bolts are now only hand-tight. Instructions like these are no longer included in the instruction manuals like they were 50+ years ago. Mostly because newer gasket material do not flex as much with the heating cycles as the older fiber gaskets do. However you can still find 8 to 12 year old boilers that look like they are over 30 years old as a result of those loose coil gaskets.
Edward Young Retired
After you make that expensive repair and you still have the same problem, What will you check next?
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Those bolts are a real problem. I come across boilers all the time less than ten years old with or without coils and they are leaking because nobody tightens the bolts after the first year of operation.
Quite often the bolts are so loose they can be completely unscrewed without any tools! Since everyone ignores the installation instructions perhaps it might be a good idea if the manufacturers put a large sticker or something like that on the boiler that would be more difficult to be ignored.
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I'm sure the bolts are often the problem, but not in this person's case it seems…it's the fitting which is going to get addressed.
NJ Steam Homeowner.
See my sight glass boiler videos: https://bit.ly/3sZW1el2 -
yet. the retorquing probably has far mor to no one actually using a torque wrench or having a spec than the gasket compressing in itself. stuff sometimes has one spec for new and another for reusing a gasket.
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I’m with you. I almost wrote (yet) on my reply 😅
NJ Steam Homeowner.
See my sight glass boiler videos: https://bit.ly/3sZW1el0
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