Full Chimney Rebuild — Westfield
Project Intro
The owners of a 1910 craftsman bungalow in Westfield called Alpha Pro Construction LLC after a home inspection revealed serious structural deterioration in their primary chimney. Brick spalling, failed mortar joints, and a cracked crown had allowed water infiltration into the chimney stack for years, eroding the interior masonry and rendering the fireplace unsafe to use.
After evaluating the extent of the damage, we recommended a full demolition and rebuild from the roofline up rather than a patchwork repair. The rebuild would include a new stainless steel flexible liner, properly sized for the fireplace insert, and a new concrete crown with a 2-inch overhang to shed water away from the stack.
- Full Stack Rebuild from Roofline
- Period-Matched Used Brick
- New Stainless Steel Flexible Liner
- Waterproof Crown & Cap Installation
Challenge & Solution
The chimney was located at the center ridge of the home, requiring scaffolding that bridged the full width of the roof. The homeowners also requested that replacement brick closely match the original, which was a 1910-era “used” brick with a distinctive weathered patina — no longer in standard production.
Our masonry team sourced a matching reclaimed brick from a demolition salvage yard, selecting over 800 pieces by hand to find the right color and texture match. The finished chimney is visually indistinguishable from the original, and the stainless liner allows the homeowners to use their fireplace safely for the first time in over a decade.
- Ridge Scaffolding System
- Reclaimed Brick Sourcing & Matching
- Custom Crown Formed & Cast
- Liner Sized for Insert Retrofit
Working Process
Demolition & Prep
Stack carefully demolished to roofline; flashing area cleaned and new counterflashing base set.
Masonry Rebuild
Reclaimed brick laid in running bond with Type S mortar; stack plumbed and corners laser-checked.
Crown, Cap & Liner
Concrete crown poured with drip edge, stainless cap installed, and flexible liner connected to insert.
Delivering Results
The rebuilt chimney is structurally sound, watertight, and historically faithful to the home’s original character. The homeowners lit their first fire in the fireplace the same week the project was completed — a moment they described as “priceless” after years of having it condemned by inspectors.
Alpha Pro Construction LLC’s masonry expertise and willingness to go the extra mile sourcing period-matched materials earned a 5-star review and a follow-on contract for exterior brick repointing on the same property.
