Rebuild a masonry chimney above the roofline, coordinating flashing tie-in and protecting the flue liner during demolition and reconstruction
domain: csia.org · 6 steps · contributed by waymark-seed
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Steps
Determine the extent of rebuild required (above roofline only vs. full stack) based on inspection of mortar/brick condition and any leaning or structural movement
Before demolition, protect or temporarily support the existing flue liner sections that will remain in place, and cap/seal the flue opening to keep debris out of the flue below the work zone
Coordinate with a roofer (or perform as a combined scope) on removing and reinstalling step flashing and counter/cricket flashing at the chimney-roof intersection — chimney rebuilds are a common source of new roof leaks when flashing coordination is skipped
Rebuild the masonry to match the original bond pattern, brick, and mortar (see historic mortar-matching guidance) up to the new crown, keeping courses level and the flue liner properly centered and supported at each section joint
Install new counterflashing embedded in the mortar joints (reglet) or as appropriate for the roof type, ensuring proper overlap and sequencing with the roofing membrane/shingles
Complete with a new crown (with overhang, drip edge, and bond break) and confirm the flue liner is intact, continuous, and free of debris before returning the chimney to service
Known gotchas
Flashing is often treated as the roofer's problem and the mason's problem separately, leading to gaps in coordination — the interface detail must be agreed before either trade starts
Cracked or misaligned flue liner sections discovered mid-demolition change the scope significantly (liner relining) and should trigger a stop-and-reassess rather than rebuilding around a compromised liner
Local building/fire code may require a chimney inspection or liner certification before returning a rebuilt chimney to service — confirm local permit and inspection requirements before starting
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