Properly
preparing a spalled chimney for stone veneer in Michigan is crucial because of the state’s extreme freeze-thaw cycles. The process requires reinforcing the existing structure and creating a stable, weatherproof substrate for the veneer. The extent of the prep work depends on the severity of the spalling.
Repair the spalled chimney
Before you can begin, a professional chimney sweep should inspect the entire structure to identify the source of the moisture that caused the spalling and assess the extent of the damage.
Remove all loose material. Use a wire brush, hammer, and chisel to remove any loose or flaking brick and crumbling mortar.
Repair mortar joints (tuckpointing). For minor mortar deterioration, tuckpointing—the process of removing old mortar and replacing it with new—will strengthen the chimney. Use a Type S mortar for added strength in Michigan’s freeze-thaw climate.
Replace severely damaged bricks. If spalling has affected more than just the surface of the brick, the individual units will need to be replaced with new ones.
Rebuild extensively damaged sections. If the damage is widespread, involving large sections of the chimney, a partial or complete rebuild may be necessary to ensure its structural integrity.
Prepare for the stone veneer installation
Once the chimney’s underlying structure is sound, you can prepare the surface for the veneer.
Install a moisture barrier. Cover the entire chimney with a water-resistive barrier, such as building wrap or waterproof ice and water shield, and secure it. This is critical for preventing moisture damage in the future.
Attach a metal lath. Secure a galvanized metal lath over the moisture barrier using masonry screws or nails. This provides a strong mechanical bond for the mortar.
Apply the scratch coat. Using a Type N or Type S masonry cement, apply a 1/2 to 3/4 inch scratch coat of mortar over the lath. Push the mortar firmly through the mesh.
Score the scratch coat. While the mortar is still wet, use a notched trowel to drag horizontal grooves into the surface. This “scratch” texture dramatically improves the adhesion for the next layer.
Allow the scratch coat to cure. Let the mortar cure for at least 24 to 48 hours before proceeding with the installation.