Chase Cover Replacement

The Manufacturing Process of Chase Covers: Precision, Durability, and Protection

Chase covers protect chimneys from water damage, debris, and deterioration. While they may seem like simple components, the process of manufacturing chase covers involves precision engineering, high-quality materials, and expert craftsmanship. At Chimney Bear, we take pride in delivering custom stainless steel chase covers that provide homeowners with long-lasting protection and durability.

Understanding how chase covers are manufactured allows homeowners to appreciate their importance and the investment in high-quality, custom-fitted covers. This article will explore the materials used, the fabrication process, quality control measures, and why custom stainless steel chase covers are the best choice for chimney protection.

Step 1: Choosing the Right Material for Chase Covers

The first step in manufacturing a durable and practical chase cover is selecting the best material. The material must resist rust, corrosion, extreme weather, and wear over time. The most common materials used include:

1. Stainless Steel (Best Choice)

• Rust & Corrosion Resistant – Ideal for long-term outdoor exposure.

• Durable & Low Maintenance – Lasts decades without deterioration.

• Professional Appearance – Complements modern and traditional homes.

• Best for Custom Fabrication – Can be shaped and customized for a perfect fit.

2. Galvanized Steel (Short-Term Solution)

• It is coated with zinc to resist rust, but the protection wears off over time.

• Prone to rusting after prolonged exposure to rain and moisture.

• It is less expensive but needs frequent replacement.

3. Aluminum (Lightweight but Weaker)

• It is resistant to rust but not as strong as stainless steel.

• Prone to denting and bending in extreme weather.

• Best for mild climates but not ideal for high-wind areas.

4. Copper (Premium & Expensive)

• Aesthetic Appeal – Develops a natural patina over time.

• Durable & Long-Lasting – Ideal for historic or luxury homes.

• High Cost & Maintenance – Requires frequent upkeep.

Stainless steel is Chimney Bear's top choice for manufacturing chase covers because it offers maximum durability, longevity, and performance.

Step 2: Precision Measurements & Custom Design

Every chimney is unique, and a properly fitted chase cover is essential for ensuring a watertight seal and optimal protection. Before manufacturing begins, technicians gather precise measurements of the chimney chase to guarantee a custom fit.

Key Measurements Taken:

• Chimney Width & Length – Ensures a snug, secure fit.

• Flue Pipe Placement – Determines proper hole cutouts for the chimney flue.

• Chimney Crown Overhang – Allows for a drip edge that directs water away from the structure.

• Slope & Cross-Break Design – Prevents water pooling and promotes efficient drainage.

The chase cover design is digitally mapped out using advanced CAD software before the metal is cut. This ensures perfect alignment, functionality, and durability.

Step 3: Cutting & Shaping the Metal

Once measurements are finalized, the stainless steel sheet is prepared for cutting and shaping. The manufacturing process follows these critical steps:

1. Laser Cutting for Precision

• Laser-guided machines cut the stainless steel with high accuracy.

• Ensures clean edges and proper alignment for a seamless fit.

• Reduces waste and allows for custom modifications.

2. Forming the Chase Cover Structure

• The cut stainless steel sheet is placed into a hydraulic press.

• The edges are bent and folded to create a 2-1/2-inch skirt with a drip edge.

• Cross-breaks (slight ridges in the cover) are added to promote water runoff.

3. Creating the Flue Opening & Storm Collar

• A hole is cut precisely to fit the chimney flue pipe.

• A storm collar is fabricated separately and later installed to seal around the flue, preventing leaks.

Step 4: Welding & Assembly

The chase cover seams are welded and reinforced to ensure maximum durability and a watertight seal. This process includes:

• Spot Welding & Seam Welding – Strengthens corners and prevents separation.

• Grinding & Smoothing – Removes sharp edges and refines the final shape.

• Adding Reinforcements – Extra supports may be added for large covers to withstand high winds.

At Chimney Bear, we ensure each weld is solid, smooth, and resistant to moisture penetration.

Step 5: Final Finishing & Quality Inspection

Before the chase cover is approved for installation, it undergoes a rigorous quality control process. This includes:

1. Corrosion Resistance Testing

• Covers are exposed to moisture and tested for rust resistance.

• Stainless steel covers pass with no visible deterioration.

2. Weight & Structural Integrity Check

• The cover is stress-tested to withstand heavy snow loads, high winds, and extreme weather conditions.

• Ensures longevity and stability.

3. Fit & Finish Inspection

• The chase cover is checked for precise cuts, smooth welds, and a professional appearance.

• Any imperfections are corrected before final approval.

Step 6: Installation & Securing the Chase Cover

Once the chase cover has passed quality control, it is ready for installation. At Chimney Bear, we follow a strict installation process to ensure a leak-proof, long-lasting fit.

Installation Steps: Ensuring a Secure and Long-Lasting Fit

At Chimney Bear, we follow a meticulous installation process to guarantee a leak-proof, secure, and durable fit for every custom stainless steel chase cover. Proper installation is crucial to ensuring maximum protection against water infiltration, structural damage, and external elements. Here’s a step-by-step breakdown of our professional chase cover installation process:

1. Cleaning the Chimney Chase

Before installing the new chase cover, our technicians thoroughly clean the chimney chase area. They remove any debris, dirt, or remnants of the old chase cover to create a clean, solid surface for a proper seal. This step prevents gaps, misalignment, or future leaks, ensuring the new cover sits perfectly flush with the chimney chase.

2. Positioning the Cover

Once the chase area is clean, the custom-fitted stainless steel chase cover is carefully positioned over the chimney chase opening. The cover must be aligned precisely to ensure a tight, secure fit, preventing potential water pooling, misalignment, or improper sealing. Proper placement is key to maintaining optimal drainage and keeping moisture out.

3. Securing with Stainless Steel Screws

After positioning, the chase cover is firmly secured using corrosion-resistant stainless steel screws. This step is essential to prevent shifting, lifting, or displacement during high winds, storms, or severe weather conditions. Our experts ensure that the screws are evenly spaced along the cover’s perimeter to create a strong, reliable attachment that can withstand years of exposure to the elements.

4. Sealing the Edges

A high-temperature, waterproof sealant is applied along the edges where the chase cover meets the chimney structure to provide an extra layer of moisture protection. This creates an airtight barrier, preventing water leaks, air infiltration, and potential rust formation. The sealant also helps compensate for minor surface imperfections, ensuring a seamless and durable fit.

5. Attaching the Storm Collar

The final step involves installing the storm collar, which wraps around the chimney flue pipe. The storm collar is secured tightly around the flue, acting as an additional moisture-resistant barrier to prevent water from dripping into the chimney chase. A bead of high-temperature sealant is applied where the storm collar meets the flue pipe, ensuring that no water seeps through, even during heavy rain or snow.

Final Inspection & Long-Term Protection

Once installed, our technicians perform a thorough final inspection, checking for secure attachment, proper alignment, and complete sealing. With a professionally installed stainless steel chase cover, your chimney will be fully shielded from rain, snow, pests, and weather-related deterioration, ensuring long-term durability and optimal performance.

Why Chimney Bear’s Custom Stainless Steel Chase Covers Stand Out

Choosing Chimney Bear means investing in top-quality craftsmanship, premium materials, and expert installation. Here’s why our stainless steel chase covers are the best option for protecting your chimney:

Custom Fit for Maximum Protection – Eliminates leaks and ensures long-term durability.

Rust-Resistant Stainless Steel – Outlasts galvanized and aluminum alternatives.

Cross-Break & Drip Edge Design – Enhances water runoff and prevents pooling.

Lifetime Warranty – Guaranteed protection for years to come.

Certified Installation by Experts – Ensures a perfect, leak-proof fit.

Get a Custom Stainless Steel Chase Cover Installed Today!

If you’re looking for a durable, custom-fitted chase cover, Chimney Bear is here to help!