When a Crystal Lake homeowner called RCC Masonry & Concrete after finding brick fragments in their yard, they knew something was wrong with their chimney — they just didn't know how bad it had gotten. What started as "a few loose bricks" turned out to be a chimney that needed a complete rebuild above the roofline.
The Problem: Years of Neglected Freeze-Thaw Damage
Our assessment revealed severe deterioration on all four sides of the chimney stack. The crown had multiple cracks — some over ¼ inch wide — that had been allowing water into the chimney structure for years. The freeze-thaw cycles had done their work: nearly every mortar joint was compromised, and 30+ bricks had spalled so severely that their faces had completely detached.
The flashing — the metal seal between chimney and roof — had rusted through and separated from both surfaces. Water had been running down the chimney and into the roof structure, causing hidden water damage to the framing and ceiling below.
Project Overview
Day 1: Demolition & Assessment
After setting up roof protection and scaffolding, our crew carefully demolished the chimney down to the roofline — the last point where the bricks and mortar were still structurally sound. We inspected the flue liner (which was fortunately still intact) and prepared the base course for the rebuild. The damaged flashing was completely removed.
Day 2–3: Rebuilding
Using color-matched bricks and Type N mortar (appropriate for above-grade exterior chimney work), our masons rebuilt the chimney course by course. Every joint was tooled to a concave profile for maximum water shedding. We installed stainless steel counter-flashing integrated into the mortar joints — far superior to surface-mounted flashing that relies on caulk.
Day 4: Crown, Cap & Cleanup
The new crown was poured with a 2-inch overhang beyond the brick face and a drip edge to direct water away from the chimney walls. We used a fiber-reinforced crown mix designed to resist cracking. A stainless steel chimney cap was installed to prevent rain, snow, and animals from entering the flue. Finally, we installed step flashing and a new cricket (diverter) on the uphill side of the chimney.
The Result
The homeowner now has a chimney built to last 50+ years with proper maintenance. The new crown, flashing, and cap work together to keep water out — addressing the root cause of the original failure. The brick match is seamless, and the chimney looks as good as (or better than) the day the house was built.
The Takeaway
This chimney rebuild could have been prevented with regular maintenance. Annual inspections, timely tuckpointing, and prompt crown repair would have cost a fraction of the full rebuild. The lesson: don't ignore your chimney. It's the most exposed masonry on your home, and early repairs are always cheaper than rebuilds.
Need a chimney inspection or repair? RCC Masonry & Concrete serves all of McHenry County and Lake County. Call (224) 441-5284 for a free assessment.