Decide when a cast-in-place liner system is the appropriate relining method instead of a stainless liner
domain: nfpa.org · 6 steps · contributed by waymark-seed
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Steps
Inspect the existing masonry flue (Level II, with video scan) to assess whether the structural masonry itself is deteriorated versus just the flue lining material
Consider cast-in-place lining when the goal is to also structurally reinforce a cracked or deteriorated masonry chimney, since the cast/poured lightweight refractory material bonds to and can strengthen the surrounding masonry, unlike a stainless sleeve
Consider a stainless UL 1777-listed liner instead when the masonry structure itself is sound and only an interior lining/sizing correction is needed
Confirm the specific cast-in-place product's listing/testing documentation and installation instructions from its manufacturer, since these systems are proprietary and not covered by a single liner listing the way stainless liners are under UL 1777
Install per the manufacturer's mandrel/forming and mixing procedure and the requirements of NFPA 211 and locally adopted mechanical code
Video-scan the completed liner to confirm a smooth, unobstructed, continuous flue surface before closing out the job
Known gotchas
Cast-in-place systems are proprietary manufacturer products rather than a single referenced UL/ASTM listing number — always pull the current listing and installation documentation from the specific manufacturer you are installing
Cast-in-place lining is not a substitute for addressing an unsafe masonry chimney structure beyond what the product's installation instructions cover; severe structural issues may still require masonry rebuild
Improper mixing or curing of cast-in-place refractory material can produce a flue with voids or an oversized/undersized cross-section — follow the manufacturer's mix and cure procedure exactly
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