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Causes of Spalling Chimney Bricks

The word “spalling” might not be familiar but the symptoms are easy to identify with a simple walk outside to look at your chimney.  Chimney spalling is the deterioration of the bricks or mortar of a chimney.  The spalling of chimney bricks is a common problem that can lead to significant chimney damage and extensive repairs.   It is essential that homeowners understand the cause of chimney spalling and how to fix it.

What is Chimney Spalling?

Spalling is the term used to describe bricks that have begun to crumble and dislodge. Damage to the exterior brick surface is usually the first sign.

When you look at your brick chimney, does it look like it used to?  Spalling refers to the deterioration of the brick, mortar, or blocks making up a structure.  From a distance, you may only notice that something doesn’t look right.  Closer examination often reveals the symptoms of spalling.

• flaking surfaces

• cracks in the mortar, bricks, or blocks

• chunks of brick or block missing

• pieces of your chimney on the ground

What Causes Chimney Spalling?

When water freezes, it expands.  The freeze-thaw cycle can split a boulder.  The same cycle that splits boulders does similar damage to any bricks in your chimney.  There are several ways that destructive moisture gets into chimney bricks.  Very old bricks are prone to spalling after years of wear and weakening.

• Older bricks may be softer and lack the glazing that protects the surface.  The same issue can arise from newer homes that were built using salvaged bricks.  The salvaged bricks may not have been designed for exterior use at all.

• Improper pressure washing can damage the surface of your bricks.  The high pressure pushes water into microscopic crevices, and the next freeze expands the cracks.

• Leaks in your gutters, chimney flashing, or crown let water into the structure of your chimney, and this creates more places for spalling to occur.

• Storm damage from wind, debris, and hail can create avenues for water to enter your chimney bricks.

• Inferior mortar: Cheap or incorrectly applied mortar used to build the chimney can “squeeze” the bricks during freeze/thaw cycles and cause cracking.

• Issues with the house: Normal house-settling as well as settling due to a structural problem with the brick walls of the home can lead to spalling.

• Salvaged bricks: Re-used bricks are more prone to damage than new, high-quality bricks.

• Badly constructed chimney: If the chimney is poorly constructed, the bricks and mortar may not hold up to the effects of freeze/thaw cycles.

Other factors can contribute to spalling bricks.  A professional inspection is the only sure way to learn what’s causing the problem.

The result of loose and damaged bricks

A big concern for chimney sweeps when looking at a damaged chimney is ongoing water infiltration.  The more water that can get into the bricks and mortar, the more damage you can expect down the line.  Leaky chimneys can allow water to run into the flue and begin a cycle of internal decay.  Compromised bricks trap and hold moisture, which easily can lead to the growth of dangerous mold, mildew and bacteria.

Additionally, a significant chimney leak can cause water to spread to vulnerable areas of the home and result in rotting and decay to wall boards, insulation, ceilings and more.  Finally, if left unattended, spalling bricks can cause a chimney to begin to lean to one side and eventually collapse.  It’s a good idea to periodically look over your chimney structure to check for spalling bricks.  In some cases, signs of water infiltration are easier to spot than brick damage.

How Do You Fix Spalling Chimney Bricks?

During your annual chimney inspection, a professional will examine the inner and outer surfaces of the chimney along with surrounding flashing, etc.  Their training and experience help identify all areas of concern.  Cracks in a chimney crown, pitting in bricks, flaking surfaces, and other symptoms are looked at in context.

• Chimney flashing may need to be repaired.

• A chimney cap may need to be replaced or added to keep the rain out of the chimney.

• Mortar or crowns may need to be repaired with materials containing waterproofing sealant to prevent moisture away.

• Missing bricks or mortar may need to be replaced and sealed.

• If the damage is extensive, the chimney may need to be rebuilt.

For minor brick/mortar damage, a waterproof sealant can be applied to prevent more water from getting into the cracked areas.  This won’t fix existing brick damage, but it will keep water out of the system.

A process called tuckpointing often is useful in repairing chimneys where sections of bricks and mortar are missing.  This chimney repair work involves adding new, strong mortar to open areas to restore structural soundness to the chimney.  If considerable masonry damage exists, it may be necessary to rebuild parts of the chimney or the entire structure. In these cases, chimney service professionals may recommend a more extensive chimney inspection to understand the extent of the damage to the masonry and the home itself.

When you see spalling chimney bricks on your property, you have evidence that damage is occurring.  It is important to hire a professional.  Repairing that damage quickly will keep the damage from getting worse.  Regular inspections and maintenance are the key to preventing spalling chimney bricks.