Mutual Materials Redondo Gray Chimney Rebuild at the Roofline – Sellwood–Moreland, SE Portland

Full Chimney Reconstruction, Leak Repair & Custom Stainless Steel Cap Installation

Project Overview: Roofline Chimney Rebuild to Resolve Active Water Intrusion

A homeowner in the Sellwood–Moreland neighborhood of SE Portland contacted Portland Chimney Inc. after noticing persistent leaks and moisture damage inside their home. Their aging chimney—constructed decades earlier—had deteriorated to the point where water was passing through loose bricks, missing mortar, and inadequate flashing. The crown had completely failed, leaving the flue system unprotected from direct rainfall.

To restore the chimney’s structural integrity and prevent continued water intrusion, our team performed a full roofline chimney rebuild using high-quality materials from Mutual Materials and completed the project with a custom stainless steel chimney cap, precise step flashing, and a modern crown built to current industry standards.

The Problem: Water Damage, Loose Bricks & Failing Flashing

During our initial inspection, the chimney showed multiple signs of long-term deterioration:

Loose and unstable bricks around the upper 30 courses
Missing crown, exposing the flue tile directly to rain
Improper or outdated flashing, allowing water to enter the roof structure
Evidence of leaks inside the home, especially after heavy storms
Mortar joints eroded from years of exposure

Chimney problems like these are extremely common in the Sellwood–Moreland area, where many homes were built in the early to mid-1900s. Older chimneys often lack modern crowns, proper step flashing, and water-resistant brick options, which makes them especially vulnerable in Portland’s wet climate.

Because the chimney had reached a point where spot repairs would not be enough, we recommended a complete roofline rebuild using durable, color-matched materials designed to withstand moisture and seasonal temperature swings.

Our Solution: Roofline Rebuild Using Mutual Materials Redondo Gray Brick

To create a long-lasting, watertight chimney structure, the project included a full teardown and reconstruction of approximately 8×30 bricks, using a controlled and staged process to protect the home and ensure safety.

1. Safe Access & Site Preparation

Because the chimney was positioned along the side wall of the home, we erected professional-grade scaffolding to ensure secure access and stable footing during demolition and rebuild. This is essential for precision masonry work at roof height and allows us to maintain a clean, contained workspace throughout the project.

2. Chimney Tear-Down & Disposal

We dismantled the damaged brickwork down to a structurally sound point at the roofline. All loose, spalling, or water-damaged bricks were removed, and debris was safely lowered and disposed of off-site.
This process prevents future leaks and ensures the new brickwork bonds correctly to the remaining chimney structure.

3. Rebuilding With Premium Mutual Materials Brick

For this project, we used Mutual Materials – Redondo Gray Mission Texture bricks, chosen for their durability, aesthetic appeal, and compatibility with the home’s exterior. To achieve a clean and cohesive look, we paired the brick with a gray mortar tinted with black, providing a subtle contrast and a modern, refined finish.

Each brick was carefully laid to ensure:

Proper alignment and plumb
Tight, consistent joints
Structural strength
Even coloration and texture from course to course

4. New Crown, Flashing & Stainless Steel Chimney Cap

A proper chimney rebuild must include moisture defense components that prevent future deterioration. For long-term protection, we installed:

Custom stainless steel chimney cap fabricated to fit the exact dimensions of the crown and flue
Black step flashing, installed to modern building standards
A new crown built with water-resistant materials, sloped to shed rainwater

These upgrades collectively provide the chimney with the weather protection it previously lacked.

5. Project Timeline

With coordinated scaffolding, demolition, masonry, and metal work, the entire project was completed within 3 days.

Local Expertise: Why Roofline Chimney Rebuilds Are Common in Sellwood–Moreland

Homes in the Sellwood–Moreland district often feature classic Portland architectural styles with original masonry chimneys. After decades of exposure to the Pacific Northwest’s rain-heavy climate, many of these chimneys develop:

Mortar erosion
Loose brick courses
Missing or outdated crowns
Failed flashing
Water intrusion into interior walls

A roofline rebuild is often the most effective solution—one that restores structural safety, eliminates moisture entry, and prevents thousands of dollars in potential interior damage.
Portland Chimney Inc. specializes in these rebuilds, combining modern materials with traditional masonry craftsmanship.

Final Results: A Strong, Leak-Free & Beautifully Rebuilt Chimney

By the end of the project, the homeowner received a completely renewed chimney designed to last for many decades. The Redondo Gray brick blends seamlessly with the home’s exterior, while the tinted mortar and black step flashing create a clean, modern visual profile. The custom stainless steel cap tops the chimney with both functionality and style, offering superior rain protection and preventing animal entry.

Most importantly, the water intrusion issue was fully resolved, and the new chimney structure now meets current safety and building standards.