Chimney Rebuild Case Studies
Structural chimney reconstruction performed the correct way — footing to crown, plumb alignment,
full-bed masonry, copper integration, and slate detailing. These examples show how Heritstone
approaches the highest-risk exterior structure on a heritage home.
Case Study 1 — Full-Height Structural Rebuild
This chimney required removal and reconstruction from the footing due to lean, mortar loss,
and incorrect crown geometry. The rebuild restored structural alignment and proper water management.
- Full teardown to decking
- Footing exposed, stabilized, and re-poured
- Base reconstructed in full-bed sandstone
- Brick shaft laid in lime mortar with through-stones
- Hand-formed copper crown installed
- Counter-flashing cut into masonry reglets
Result: A corrected, load-bearing chimney designed for another century.
Case Study 2 — Leaning Chimney Realignment
The chimney had drifted several inches off plumb but was structurally salvageable. We preserved original
stone while correcting alignment and rebuilding upper courses.
- Laser plumb correction
- Upper stone/brick courses dismantled and rebuilt
- Structural ties inserted into existing mass
- Copper cricket installed to correct water flow
- Slate perimeter lifted and reset with proper bib flashings
Result: Structural correction while maintaining original stonework.
Case Study 3 — Chimney Base Failure + Structural Wall Rebuild
A collapsing firebox support wall caused the chimney base to rotate. Using the Heritstone Structural Wall System,
both components were rebuilt to correct load transfer.
- Failing firebox support wall removed and replaced
- New structural sandstone chimney base installed
- Brick shaft realigned and rebuilt
- Continuous copper gutter tie-ins corrected
- Slate perimeter properly reset
Result: Full mass stabilization of the chimney and adjoining wall structure.
Case Study 4 — Upper Section Reconstruction + Copper Crown
Severe spalling from incompatible mortar required a top-third reconstruction and a true copper crown.
- Damaged upper masonry removed
- Rebuilt using matching stone/brick with lime mortar
- One-piece copper crown fabricated
- Copper counter-flashing installed
- Slate perimeter corrected
Result: Permanent rebuild replacing years of patchwork failure.
Case Study 5 — New Estate Chimney Construction
A ground-up chimney built as part of a stone estate expansion, using full-bed materials and
heritage roof integration.
- Reinforced concrete footing
- Full-bed sandstone base with through-stone bonding
- Brick flue and firebox built to heritage dimensions
- Slate and copper integrated into chimney geometry
- Copper scuppers and valley pans fabricated
Result: A chimney built as a true structural column, not decorative masonry.
Materials Used in All Rebuilds
- Full-bed sandstone, limestone or period-correct brick
- Lime mortar for heritage homes
- Through-stones for structural bonding
- 20 oz copper crowns, flashings & pans
- Slate perimeter reinstated with correct bib transitions
- No veneers, no caps, no sealants-as-repair
Request a Heritage Chimney Assessment
Most chimney failures begin at the footing or at slate/copper transitions. A Heritage Site Visit
identifies structural issues, rebuild requirements, and long-term corrective options.
Call: 440-448-5057
Email: contact@heritstone.com