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Chimney Renovation With Heatshield
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/2.jpgChunks of saturated creosote ash on top of the stove looked like evidence of a problem.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/3.jpgThe extension from the top of the stove does not reach to the flue tile. Wood stoves installed in a fireplace should have a properly sized flue liner from the stove outlet to the top of the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/4.jpgThe back of the chimney had some large cracks as the result of a lightning strike nearby. This is the original reason we were called out to inspect the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/5.jpgThese cracks, while significant, are less of a hazard than the wood stove on the other side of the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/6.jpgCracks that run through the brick are a result of expansion of the masonry. In this case, lightning was the cause, but similar cracks can be caused by chimney fires or improper installation of the damper or lintels during construction.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/7.jpgAbove the roof, the chimney had the typical construction defects,
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/8.jpgThe mortar wash is porous and cracked, permitting water penetration of the masonry structure. The top course of brick is also stepped in, creating a shelf that collects water . These are the two most common construction defects that lead to premature deterioration of chimneys in our area.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/9.jpgOnce uncovered, the flue interior was heavily coated with creosote glaze.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/10.jpgThis shiny black stuff is condensed smoke and is highly flammable. This type of buildup is what makes operating an improperly installed wood stove so hazardous.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/11.jpgThe puffiness lower down in the flue indicates the residue from a previous flue fire. The creosote ash has been saturated with new creosote by continued use of the installation after the flue fire.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/12.jpgThe joints between flue tiles are not solidly mortared together to make a gas tight conduit. These gaps allow buildup of creosote outside the flue tile.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/13.jpgThe homeowner decided to install a central heating system and renovate the fireplace for worry free use. The first step in the process is removing the old stove. Doing so reveals the firebox.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/14.jpgLooking up the flue from above the damper reveals an improperly constructed smoke chamber and the creosote encrusted flue.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/15.jpgSweeping the chimney shows that the smoke chamber is definitely not parged smooth. Corbels and cores exposed in the brick will create turbulence in the flow of flue gases, reducing efficiency and increasing residence time of the gases in the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/16.jpgWe were able to get most of the glazed creosote from the flue interior. Cleaning up the flue reveals the cracks in the tiles caused by the flue fire.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/17.jpgView down the flue after applying the HeatShield scratch coat. This initial coat of HeatShield Cerfractory Flue Sealant settles the dust in the flue and creates a textured surface for the finish coat to bond to.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/18.jpgHere you can see that we have removed the mortar wash and top course of brick from the chimney top, and then applied the final coat of HeatShield.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/19.jpgHeatShield is a ceramic refractory, or cerfractory, cement. It dries very hard and seals the flue tiles to make a gas tight, acid resistant flue. As you can see here, all the cracks and gaps in the flue have been sealed with HeatShield.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/20.jpgNow that the flue has been sealed, we need to attend to the turbulent smoke chamber.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/21.jpgThe smoke chamber should be parged smooth with mortar to make a laminar air flow up the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/22.jpgFlue tiles should be seated on solid masonry units on all sides, avoiding gaps in the flue that can allow flue gases to escape.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/23.jpgThe smoke chamber looks much nicer after parging with ChamberCoat insulating cement.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/24.jpgChamberCoat is at least an inch thick, thoroughly insulating the smoke chamber and preventing heat pass through to any combustible materials that may be too close to the smoke chamber.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/25.jpgThis is more like what a smoke chamber should look like.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/26.jpgRemember those cracks in the back of the chimney structure?
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/27.jpgWe cut out all the damaged brick.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/28.jpgThe brick on the back of the firebox were not full bricks. This makes them a lot easier to crack and a lot harder to remove and replace.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/29.jpgAt the top of the chimney we poured a concrete crown where the top row of brick once was.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/30.jpgA proper crown protects the chimney from water penetration. Removing the top course of brick gets rid of the stepped in brick at the top and gives us matching brick to replace on the back of the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/31.jpgThe forms are filled with concrete and the concrete is edged and smoothed.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/32.jpgThe brick that were once at the top of the chimney are now in the back of the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/33.jpgUsing brick from the same structure for repairs is the easiest way to match the color and texture of the brick.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/34.jpgThe next day, the crown forms are removed and the crown is finished up. ChimneySaver water repellent is also applied to the chimney.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/35.jpgAn IceBreaker damper cap provides both a cap and a damper to the fireplace.
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https://chimcheree.com/wp-content/uploads/slideshow-gallery/36.jpgAfter a day, it's difficult to tell which bricks have been replaced.
A home in Greenville was struck by lightning last Summer and some large cracks appeared in the chimney exterior as a result. We were called out to inspect the chimney and make sure it was suitable for use.
The cracks were pretty substantial, but not really a cause for significant concern. The improperly installed wood stove insert and residue of a previous flue fire were cause for concern. We explained our concerns to the homeowner and the decision was made to remove the wood stove and renovate the fireplace for worry free use.
To repair the damaged flue, we resurfaced the flue tiles with HeatShield Cerfractory Sealant and parged the smoke chamber with ChamberCoat.
On the exterior, we removed the top course of brick from the chimney and poured a proper concrete crown. The top course of brick was stepped in and encouraged water penetration of the chimney structure.
We cut the damaged brick from the chimney exterior and replaced them with brick taken from the top of the chimney.As a result, the replacement bricks matched perfectly.
A top sealing IceBreaker damper cap covers the flue and will reduce energy loss from the home when the fireplace is not in use.