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Chimney Rebuild, Repointing & Copper Flashing – Totowa NJ
Project Overview
Full chimney restoration on a residential home in Totowa, Passaic County, NJ. The chimney had deteriorated mortar joints, spalling brick, a failed cap, and corroded flashing that was directing water into the home. Duraproof erected scaffolding for safe access and performed a complete rebuild of the upper chimney section, full tuckpointing, new copper flashing, and a new concrete cap.
Analysis
The chimney had not been maintained in over 20 years. Freeze-thaw cycles had expanded cracked mortar joints, allowing water infiltration that was staining interior walls. The top two courses of brick were unstable and needed full reconstruction. The existing counter flashing had corroded away, and the step flashing was improperly installed by a previous contractor — the primary source of a recurring roof leak.
Process
Day 1: Scaffolding and chimney assessment. Day 2–3: Upper brick demolition and rebuild. Day 4–5: Full tuckpointing. Day 6: Copper flashing installation. Day 7: Concrete cap and waterproof sealer. Day 8: Scaffold removal and clean-up.
Outcome
The chimney is now structurally sound, fully waterproofed, and properly flashed. Interior water staining has stopped. The matching brick and mortar restoration preserved the home historic character while delivering modern watertight performance.
Project Details
Materials Used
Matching red clay brick, Type S masonry mortar, copper step flashing, copper counter flashing, pre-formed concrete chimney cap, hydraulic cement, silane-siloxane waterproof sealer
Methods & Techniques
Scaffolding erected for safe working platform. Top two unstable brick courses carefully demolished and rebuilt with matching brick and Type S mortar. All remaining mortar joints ground out 3/4" deep and repointed. New copper step flashing woven into shingles. Copper counter flashing bent and driven into mortar joints. New poured concrete cap installed. Waterproof sealer applied to entire chimney.
Key Highlights
Full scaffolding for safe elevated access | Matching brick rebuild of deteriorated courses | Copper step and counter flashing | New concrete chimney cap | Silane-siloxane waterproof sealer applied