Complete Chimney & Masonry Restoration with Premium Gas Fireplace Conversion

Project Overview

This was a large, multi-phase chimney and fireplace restoration requiring specialty access, extensive masonry work, chimney-top reconstruction, custom stainless steel fabrication, firebox restoration, professional gas-line installation coordination, firebox preparation, and installation of a premium gas fireplace system.

The chimney had deteriorated masonry, damaged architectural clay chimney pots, a failing crown, organic growth, compromised wood-burning flue conditions, and a firebox that also required restoration. The homeowner chose not to invest in relining the existing flue for continued wood-burning use. Instead, the project combined complete exterior masonry restoration with a premium gas fireplace conversion.

From initial measurements and roof-access planning through fabrication, gas coordination, masonry work, fireplace restoration, and final installation, the project took approximately one month to complete.

What We Found

• Deteriorated mortar joints and widespread exterior masonry weathering
• Cracked, damaged, and spalling bricks requiring selective replacement
• Organic growth, mildew, and staining across portions of the chimney
• A severely cracked and deteriorated crown
• Two cracked architectural clay chimney pots integrated into the flue termination
• Wood-burning flue conditions that did not support continued use in the existing configuration
• Firebox cracking and deteriorated joints requiring restoration before installation of the new gas system

Why the Clay Chimney Pots Made This More Complex

The original termination used architectural clay chimney pots rather than conventional removable caps. These pots were integrated into the clay flue termination beneath the crown, so they could not simply be lifted off and replaced.

Because both pots were cracked, proper correction required removal of the existing crown, exposure of the clay flues below, and reconstruction of the chimney top. The flue terminations then had to be extended and prepared for the new custom stainless steel multi-flue cage.

Specialty Tile-Roof Access & Protection

The home has a steep, high-value tile roof, making access a major part of the project. Standard roof traffic and conventional ladder placement could have damaged individual roofing tiles.

We built a temporary access and protection system specifically for the property using secured ladders, bridging, work platforms, braces, ropes, and protective padding. The setup allowed our technicians to reach and work around the chimney while minimizing concentrated loads on the finished roof.

Complete Masonry Restoration

The chimney then received extensive masonry restoration. Deteriorated mortar was removed to the appropriate depth so new mortar could be properly installed. Damaged and spalling bricks were selectively replaced where necessary, and compromised joints throughout the chimney were restored.

The photograph below shows the chimney after the deteriorated mortar had been raked out and before the new mortar joints were installed. This is a work-in-progress stage, not a finished result.

Following preparation, the masonry was repointed and restored. Organic growth, staining, and surface contamination were also addressed as part of bringing the exterior back to a cleaner and more uniform condition.

Custom Stainless Steel Multi-Flue Cage

Once the old clay pots and deteriorated crown were removed and the chimney top was reconstructed, final measurements could be taken for a custom stainless steel multi-flue cap.

This was a made-to-order component fabricated specifically for the dimensions and flue configuration of this chimney. It replaced the deteriorated clay-pot arrangement with a durable custom stainless steel multi-flue cage that protects the flues from direct precipitation, debris, and animal entry.

Firebox Restoration & Premium Gas Conversion

The restoration continued inside the home. The existing firebox contained cracking and deteriorated mortar joints. These areas were repaired and tuck-pointed as necessary, and the firebox was finished with a high-temperature ceramic coating before the new gas system was installed.

The homeowner selected a premium 30-inch Grand Canyon IPI gas fireplace system. IPI, or Intermittent Pilot Ignition, provides electronic ignition rather than relying on a continuously burning standing pilot. The system includes remote operation and variable flame control for convenient operation and a more refined finished installation.

A Multi-Phase Project Requiring Extensive Coordination

This project required far more than the time physically spent performing masonry work. Different phases depended on the completion of earlier work, and several components had to be measured, ordered, fabricated, and installed on separate visits.

• Initial chimney, fireplace, and internal flue evaluation
• Multiple roof visits, measurements, and project planning
• Specialty tile-roof access design and property protection
• Removal of the cracked clay chimney pots and deteriorated crown
• Clay flue extension and chimney-top reconstruction
• Complete exterior masonry restoration and selective brick replacement
• Masonry cleaning and treatment of organic growth
• Field measurement and custom fabrication of the stainless steel multi-flue cap
• Firebox repair, tuck-pointing, and high-temperature ceramic coating
• Professional gas-line installation and coordination with the licensed trade
• Installation of the premium 30-inch IPI gas fireplace system
• Electronic ignition, remote-control, and variable flame setup
• Final testing, cleanup, and removal of the specialty roof-access system

Approximately One Month From Planning to Completion

This was not a one-day repair. Approximately one month was required from the planning and ordering stages through final completion. Final cap measurements could only be taken after the chimney top was opened and reconstructed, custom stainless steel fabrication required lead time, the gas-line work and fireplace installation had to be carefully scheduled and coordinated, and exterior masonry work remained dependent on suitable weather.

The finished project reflects the coordination of masonry craftsmanship, specialty roof access, custom fabrication, fireplace work, gas installation, multiple trades, and careful sequencing from the first inspection through final completion.

The Finished Result

What began as an aging chimney with deteriorated masonry, cracked clay chimney pots, a failing crown, compromised wood-burning flue conditions, organic growth, damaged brickwork, and a deteriorated firebox was transformed into a restored masonry chimney and modern gas fireplace system.

The exterior masonry was restored while preserving the architectural character of the home. The original clay-pot termination was replaced with a custom stainless steel multi-flue cap, the chimney top was reconstructed, and the specialty tile roof was protected throughout the work.

Inside the home, the firebox was restored and ceramic coated before receiving the premium 30-inch IPI gas system with electronic ignition, remote operation, and variable flame control.

This was not simply a chimney repair or a gas log installation. It was a complete chimney and fireplace transformation, carefully coordinated from the roofline to the firebox.