Industrial Chimney Repair & Restoration

Experienced Industrial Chimney Contractors Serving Iowa & Illinois

Industrial chimneys are critical infrastructure components that require specialized expertise to maintain and repair. At Bi-State Masonry, we provide comprehensive industrial chimney repair and restoration services for manufacturing plants, power generation facilities, institutional buildings, and commercial operations throughout the Iowa and Illinois corridor. Since 1999, our team has developed extensive experience working on smokestacks, boiler chimneys, and industrial exhaust systems that demand both technical precision and strict adherence to safety protocols.

Industrial Chimney Repair & Restoration Services

Industrial chimneys endure far more demanding conditions than residential or standard commercial chimneys. Constant exposure to high temperatures, corrosive flue gases, thermal cycling, and extreme weather creates unique deterioration patterns that require specialized repair approaches. Our commercial masonry team has the equipment, training, and experience to address these challenges safely and effectively.

We provide a full range of industrial chimney services, including:

Every industrial chimney project begins with a thorough inspection and assessment. We evaluate the structural integrity of the masonry, examine the condition of mortar joints, check for spalling or deteriorating brick, assess the flue liner condition, and identify any areas of concern that could affect performance or safety. This detailed evaluation allows us to develop repair specifications tailored to each chimney's specific needs and operating conditions.

Types of Industrial Chimneys We Service

Bi-State Masonry works on a wide variety of industrial and commercial chimney systems. Each type presents its own set of challenges related to construction materials, operating temperatures, exposure to corrosive elements, and accessibility requirements.

Manufacturing Plant Smokestacks

Large manufacturing facilities often rely on tall masonry smokestacks to vent exhaust gases from production processes. These structures may be constructed from brick, concrete block, or poured concrete, and can range from 50 feet to well over 100 feet in height. We have the equipment and personnel to safely access and repair smokestacks of any height, including the use of suspended scaffolding, boom lifts, and industrial climbing equipment when necessary.

Boiler Room Chimneys

Heating plants, hospitals, universities, and large commercial buildings frequently use boiler systems with dedicated masonry chimneys. These chimneys experience significant thermal stress from constant heating and cooling cycles throughout the heating season. Over time, this thermal cycling causes mortar deterioration, brick spalling, and liner damage. We repair boiler chimneys to restore their structural integrity and ensure safe, efficient operation.

Incinerator Stacks

Incinerator chimneys face particularly harsh conditions due to the extreme temperatures and corrosive byproducts of combustion. The interior surfaces are especially vulnerable to chemical attack and erosion. Restoration work on incinerator stacks often includes specialized refractory repairs and protective coatings designed to withstand these aggressive conditions.

Multi-Flue Commercial Chimneys

Larger commercial and institutional buildings may have chimneys with multiple flues serving different heating appliances or systems. These complex structures require careful coordination during repairs to ensure each flue maintains proper draft and separation. We have extensive experience working on multi-flue systems for schools, universities, hospitals, and government buildings throughout Iowa and Illinois.

Common Industrial Chimney Problems

Industrial chimneys deteriorate through several mechanisms, many of which are accelerated by the demanding operating conditions these structures face. Understanding these deterioration patterns helps facility managers recognize when repair work is needed and what type of restoration is appropriate.

Mortar Joint Deterioration

The mortar joints in industrial chimneys are often the first component to show signs of wear. Constant exposure to heat, moisture, and corrosive flue gases breaks down the mortar over time. As joints deteriorate, water penetration increases, accelerating damage to the surrounding masonry. Tuckpointing, the process of removing deteriorated mortar and replacing it with new material is one of our most common industrial chimney repairs.

Brick Spalling and Erosion

Spalling occurs when the face of a brick flakes off or crumbles away. In industrial chimneys, spalling is often caused by moisture penetration combined with freeze-thaw cycles, exposure to acidic flue gases, or the use of inappropriate brick for high-temperature applications. We replace damaged brick with appropriate materials rated for the specific operating conditions of each chimney.

Structural Cracking

Cracks in industrial chimneys can result from thermal stress, foundation settlement, wind loading, or seismic activity. Vertical cracks often indicate thermal movement, while horizontal cracks may suggest more serious structural issues. We assess the cause and severity of cracking to determine whether repairs can be made in place or whether more extensive reconstruction is necessary.

Flue Liner Damage

The flue liner protects the masonry structure from direct exposure to corrosive flue gases and heat. When liners crack, deteriorate, or separate from the chimney walls, the surrounding masonry becomes vulnerable to accelerated deterioration. We repair and replace flue liners using materials appropriate for each chimney's operating conditions, including clay tile, stainless steel, and specialized refractory materials.

Crown and Cap Deterioration

The crown—the concrete or mortar cap at the top of a masonry chimney—is critically important for preventing water infiltration. Industrial chimney crowns often deteriorate faster than residential crowns due to greater exposure to thermal stress and corrosive elements. We repair or rebuild deteriorated crowns using durable materials designed to withstand industrial conditions.

Our Industrial Chimney Restoration Process

Successful industrial chimney restoration requires careful planning, proper materials selection, and skilled execution. Our approach ensures that repairs address the root causes of deterioration while meeting the operational requirements of each facility.

Inspection and Assessment

We begin every project with a comprehensive inspection of the chimney structure. This includes visual examination of exterior surfaces, interior flue inspection (using video equipment when necessary), evaluation of mortar joint condition, identification of structural defects, and assessment of water damage. For taller structures, we may utilize drone technology for initial assessments before deploying personnel for detailed inspection work.

Repair Specification Development

Based on our inspection findings, we develop detailed repair specifications that address each identified deficiency. These specifications identify the scope of work, materials to be used, access methods, and any special considerations related to the chimney's operating conditions. For projects involving prevailing wage requirements or public bid processes, we provide complete documentation to support the bidding process.

Access and Safety Setup

Industrial chimneys often require specialized access equipment and rigorous safety protocols. Depending on the structure's height and configuration, we may use suspended scaffolding, tube and coupler scaffolding, boom lifts, or industrial rope access techniques. Our crews are trained in confined space entry, fall protection, and other safety procedures essential for industrial chimney work.

Repair Execution

Our masons execute repairs according to the developed specifications, using materials matched to the chimney's operating conditions. For tuckpointing work, we carefully remove deteriorated mortar to the appropriate depth before installing new mortar with proper tooling and curing. Brick replacement follows similar attention to detail, with new brick selected for compatibility with existing materials and operating temperatures.

Quality Verification

Upon completion, we verify that all repair work meets the specified requirements. This may include visual inspection, mortar testing, or other quality assurance measures as appropriate for the project scope. We document completed work with photographs and provide detailed reports for facility records.

Industries We Serve

Our industrial chimney repair services support a wide range of facilities and sectors throughout the Des Moines to Chicago corridor. We have established relationships with facility managers, general contractors, and engineering firms who trust our expertise for their most demanding chimney projects.

• Manufacturing plants and factories
• Power generation facilities
• Hospitals and healthcare campuses
• Universities and educational institutions
• Municipal buildings and government facilities
• Water treatment plants and utilities
• Food processing facilities
• Warehouses and distribution centers
• Correctional facilities
• Military installations

Bi-State Masonry has completed project for several major institutions including the University of Iowa, Iowa State University, and the Iowa Department of Transportation. Our experience with institutional and government projects means we understand the documentation requirements, safety protocols, and quality standards these facilities demand.

Prevailing Wage Projects

Approximately 20 percent of our commercial work involves prevailing wage requirements under Illinois law or federal Davis-Bacon regulations. We maintain full compliance with prevailing wage requirements and certified payroll documentation for all applicable projects. Our familiarity with these requirements allows us to participate in public bid processes and deliver quality work within prevailing wage frameworks.

Frequently Asked Questions

How do I know if my industrial chimney needs repair?

Warning signs include visible mortar deterioration, spalling or crumbling brick, white staining (efflorescence) on the chimney surface, cracks in the masonry, pieces of brick or mortar accumulating at the chimney base, and water infiltration in adjacent building areas. If your chimney is more than 20 years old and has not been inspected recently, we recommend scheduling an assessment to identify any developing problems before they become more serious.

Can industrial chimney repairs be performed while the facility remains operational?

In many cases, yes. Depending on the scope of work and the chimney's configuration, we can often schedule repairs during planned maintenance shutdowns or work in phases that allow continued facility operation. We coordinate closely with facility managers to minimize disruption while ensuring worker safety and repair quality.

How long does industrial chimney restoration typically take?

Project duration varies significantly based on the chimney's size, the extent of deterioration, access requirements, and weather conditions. A moderate tuckpointing project on a boiler chimney might take one to two weeks, while comprehensive restoration of a large smokestack could require several weeks or longer. We provide detailed schedules during the proposal phase so facility managers can plan accordingly.

What is the difference between chimney repair and chimney restoration?

Repair typically refers to addressing specific deficiencies such as tuckpointing deteriorated mortar joints or replacing damaged brick in localized areas. Restoration is a more comprehensive process that returns the entire chimney to sound condition, often including repairs to the crown, flue liner, and protective treatments in addition to masonry work. We assess each chimney's condition to recommend the appropriate scope of work.

Do you provide emergency industrial chimney services?

Yes. We understand that chimney failures can create urgent safety concerns or disrupt critical operations. We respond promptly to emergency situations and can mobilize crews quickly when immediate action is necessary. Contact us directly to discuss emergency repair needs.

What geographic area do you serve for commercial chimney work?

Our commercial masonry services extend from Des Moines through the greater Chicago area, covering Iowa and Illinois. We work throughout this corridor for industrial and commercial projects, with our team traveling to job sites as needed. For larger projects, we can also accommodate work outside this primary service area.

Request a Free Industrial Chimney Assessment

Bi-State Masonry provides free estimates for all commercial and industrial chimney projects. Our assessments include a thorough inspection of your chimney structure, identification of any deterioration or deficiencies, and detailed recommendations for repair or restoration work. With over 26 years of experience serving industrial facilities throughout Iowa and Illinois, we bring the expertise and resources your project requires.

Contact us today to schedule your free industrial chimney assessment. Call (309) 786-8800 or complete our online contact form to get started.