A Fireplace Reborn: How Our Team Transformed a Failing Chimney From the Ground Up

When cracks in our clients' chimney were discovered, we investigated and found hidden water damage on the interior of the chimney extending all the way down into the fireplace. Reestablishing the fireplace's integrity would require a full rebuild — from the foundation to the final coat of paint. This project was our second fireplace replacement in a year, which earned the homeowners' confidence in our experience. We knew all we needed to begin the project plan, and had already established relationships with the few fireplace masonry experts in San Diego. Because we have all these specialty capabilities, we were able to handle all parts of the project, all the surprises, and anything that came up. 

Before Anything, a Very Detailed Scope of Work

In construction, a scope of work isn’t just a price — it’s the outline of what will actually happen on the job. Many estimates leave out important details, and those gaps often turn into surprise charges once work begins.

To avoid that, we write a scope of work that is as clear and specific as possible. If the project involves isolation barriers, framing repairs, cleanup, foundation work, or anything else that affects time and cost, it’s listed directly in the scope of work. Nothing is assumed, and nothing is hidden in vague wording.

Creating this level of detail takes time — sometimes weeks — because we review each step carefully and update the scope of work whenever questions come up. This prevents misunderstandings and makes sure everyone knows exactly what is included.

In short, our extremely detailed scope of work protects you as the homeowner and keeps the project and the cost transparent from beginning to end. The thoroughness of our scope of work exemplifies the clear communication we proactively provide every step of the way.

Step 1: Protecting the Home Before a Single Tool Comes Out

We begin every project with respect for the space. Before we began the fireplace demolition, our team  isolated and protected furniture and other items with plastic. Inside, we installed protection blankets to the flooring with a plywood topper and built a sealed isolation enclosure around the work zone to keep dust from spreading throughout the home. Outside, we covered the driveway, and shielded nearby plants and windows.

A clean job is the foundation of a quality job — and we don’t compromise on either.

We make a point to communicate with the neighbors before work begins. For a project of this size, we go door-to-door to let surrounding households know what we’ll be doing, when we’ll be there, and how we plan to minimize disruption. We reassure them that we won’t block driveways or parking, and we give them a direct contact in case they have concerns. Throughout the project, a site lead stays present to ensure the work stays orderly, respectful, and on schedule — something the homeowners appreciated just as much as the craftsmanship itself.

Step 2: Removing the Damaged Fireplace Safely and Cleanly

Once everything was protected,  we performed a controlled demolition in a surgical manner. This allowed us to avoid causing damage to the adjacent areas that must be salvaged and re-used. The water intrusion had been unkind: damaged stucco, a failing chimney structure, a compromised firebox, and even a deteriorated foundation. Piece by piece, we dismantled the failing components and hauled the debris offsite so the rebuild could begin on solid ground. 

Step 3: Waterproofing for the Future

With the structure open, we addressed the root of the problem: moisture. Our crew installed new flashing and waterproofing at the roofline — the critical junction where so many fireplaces begin to fail. By starting with better protection, we ensured this new fireplace wouldn’t repeat the mistakes of the old one.

Step 4: Building a Stronger, Modern Foundation

A fireplace is only as good as the foundation supporting it. We excavated below the old

footprint and installed a deeper, wider base reinforced with steel. After it passed city inspection, we poured the new concrete and added structural steel bands and vertical rebar required for modern seismic and building codes.

In other words: this fireplace isn’t just beautiful — it’s engineered to last and built up to today’s codes and standards.

Step 5: Rebuilding the Chimney and Firebox the Right Way

Our masons constructed a brand-new chimney using masonry block, brick, and refractory materials. The firebox was rebuilt using refractory brick and heat-resistant mortar, sized to closely match the original opening but upgraded to today’s safety standards. We added a combustion air kit, a damper, a new concrete crown, and a stainless steel spark arrester at the top.

We also replaced rotten framing, reinforced joists, and ensured all structural members met modern code.

Step 6: Repairing and Integrating the Roof

Every chimney needs a roof that blends seamlessly around it. Our roofing team repaired the surrounding deck, added new membrane materials, and tied the system into the new chimney for a watertight finish. A good fireplace rebuild always involves thoughtful roofing work — it’s a package deal.

Step 7: Matching the Exterior Finish

Outside, we rebuilt the stucco around the chimney to match the home’s existing texture and applied a custom-matched finish coat. Once cured, our painters primed and painted the chimney to seamlessly blend with the home’s exterior.

Good stucco work doesn’t call attention to itself — it simply looks like it has always belonged there.

Step 8: Elevating the Interior Hearth

Inside the living room, the transformation became personal.

We rebuilt the hearth and fireplace face using tile selected by the homeowners, added insulation, and replaced damaged flooring with custom-milled oak planks stained to match the existing hardwoods. We custom-built a handcrafted 60-inch oak mantel - out of wood the homeowners themselves selected - stained it, and sealed it in place — a true centerpiece for the room.

Fresh drywall, texture, primer, and two coats of paint tied the entire space together. The

result? A room that feels renewed, not just repaired; a job that we are very proud of, and some very satisfied clients who have continued hiring us for all their renovation projects large or small.

Step 9: Final Cleanup and Walkthrough

When the last tool was packed away, our crew swept, cleaned, and walked the homeowners through every detail of the finished fireplace. What began as a safety concern ended as a fully rebuilt, structurally sound, beautifully crafted hearth ready for decades of warmth.

A True Rebuild — and a Reminder of Why Quality Matters

Fireplace failures often start small — a little moisture, a bit of settling, a crack that wasn’t there last year — but when the entire structure needs to be rebuilt, you want a team that will handle every stage with skill and care.

From isolation to demolition, from foundation to finish trim, this project is a perfect example of the comprehensive craftsmanship HCC brings to every home repair and renovation. We did not just replace these homeowners' fireplace and chimney, we also created an ongoing business relationship. If your fireplace, chimney, or any structural part of your home needs help, we’re here to rebuild it — not just to code, but to last.