180’ BRICK CHIMNEY REPAIR & CAP INSTALLATION

Industrial Access performed comprehensive restoration and protective repairs on a 180’ radial brick chimney. The structure exhibited widespread deterioration, including defective mortar joints, aging sealants on stack exterior and around its tension bands, as well as a spalled concrete foundation around the base of the chimney. The project scope included full-height repointing and tuckpointing, lightning protection system repairs, and a full chimney cap installation. These efforts were completed to restore structural integrity, protect the chimney against environmental conditions, and prevent future safety hazards.

A higher education facility in the Midwestern United States retained Industrial Access (IA) to evaluate and repair their 180’ radial brick chimney that was recently decommissioned as the facility transitioned from a steam heating system. The stack’s aging condition still required ensured protection and maintenance to prevent it from becoming a safety concern.

A visual inspection performed by IA confirmed that the chimney exhibited deterioration consistent with prolonged environmental exposure. Identified areas of concern included defective mortar joints, degraded sealants, worn tension bands, foundation-level grout deficiencies, and compromised components of the lightning protection system (LPS). Additionally, the top of the chimney required protection, as the flue opening was vulnerable to ongoing moisture intrusion and weather-related deterioration.

To complete the chimney repairs, IA technicians utilized crane and man basket access method to safely reach elevated work areas along the full height of the structure. The crane was also used to lift and position the chimney cap in place. This approach allowed crews to efficiently mobilize personnel, materials, and equipment for the repairs, particularly in the most deteriorated upper sections of the structure. Crane access provided a stable and effective means of performing detailed restoration activities at height, supporting the safe execution of repairs across all areas of the chimney.

IA initiated the project by establishing safe access for work at elevation. A custom full chimney cap was prefabricated, coated, and installed to protect the flue and concrete crown. This will ensure that the decommissioned stack remains protected against environmental exposure and moisture intrusion.

The chimney exterior underwent targeted surface prep to facilitate repairs to deteriorated mortar joints and tension bands. IA proceeded with full-height repointing and tuckpointing of defective mortar joints. Several courses of brick at the top of the chimney were relayed to ensure structural integrity of the brick shell. The tension bands on chimney exterior were reconditioned through cleaning, removal of existing sealant, application of new sealant, and protective coating to extend their service life. Faded exterior markings were also repainted to improve the overall appearance of the structure.

In addition, LPS repairs were completed, including the replacement of down leads to ensure proper system functionality. The deteriorated grout at the chimney foundation was cleaned and replaced with repair mortar. Upon completion of structural and system repairs, a solvent-based waterproofing sealant was applied across the chimney exterior to provide long-term protection against environmental conditions.

All repairs were completed safely and efficiently, with IA crews remaining flexible to accommodate the facility’s schedule. Deterioration across the full height of the chimney was addressed, resulting in a stabilized and protected structure. The installation of a chimney cap, along with the application of a protective exterior sealant, has improved the chimney’s resistance to water infiltration and ongoing weather-related deterioration. By addressing both localized deficiencies and broader exterior wear, the project reduced the risk of continued degradation and potential safety concerns, like falling brick hazards. Ongoing inspection and maintenance will support the long-term stability and condition of the structure.