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Inspection, Repair & Maintenance Programs for Chimneys & Stacks

Chimneys and stacks are critical to the safe and efficient operation of power plants and industrial facilities. Over time, environmental and operational factors can cause deterioration, making regular inspection and maintenance essential to prevent safety incidents and costly unplanned downtime.

PULLMAN delivers comprehensive chimney and stack services designed to inspect, repair, and extend the service life of these vital structures.

As a licensed partner of STRUCTURAL TECHNOLOGIES, PULLMAN provides customized inspection programs for industrial chimneys and stacks. Our inspections identify the root causes of deterioration, evaluate structural integrity, and recommend targeted repairs to restore performance and reliability.

Our industrial chimney inspection services include:

  • Visual and drone-based inspections
  • Non-destructive testing (NDT) and core sampling
  • Flue liner and refractory evaluations
  • Structural condition assessments and reporting
  • Root cause analysis for corrosion or cracking

Regular inspections help facility operators detect issues early, schedule proactive maintenance, and prevent unexpected outages.

Supported by advanced engineering from STRUCTURAL TECHNOLOGIES, PULLMAN delivers turnkey repair and maintenance solutions for industrial chimneys and stacks. Our teams provide both internal and external repairs to improve reliability and extend service life.

Chimney repair and maintenance capabilities include:

  • Structural concrete and steel repairs
  • Liner and flue replacement or rehabilitation
  • Design and fabrication of custom access systems
  • Installation of corrosion-resistant coatings and materials
  • Chimney modernization and retrofit design for extended service life

All work is performed safely and efficiently, with minimal disruption to facility operations.

PULLMAN and STRUCTURAL TECHNOLOGIES offer a full-service Investigate–Design–Build (IDB) approach. From initial condition assessment to engineering and installation, clients benefit from a single-source solution for industrial chimney and stack projects. This integrated model helps operators reduce downtime, control costs, and ensure high-quality results. 

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Chimney Inspection Services

Chimney Field Inspections

PULLMAN offers specialized chimney and stack assessment services to help plan and prioritize repair programs in a manner that maximizes plant safety and efficiency. We provide one-time or ongoing inspections of all chimney components, including:

  • Liner Exterior / Annulus Space
  • Chimney Exterior
  • Liner(s) Interior

Inspection Reporting

When PULLMAN performs a comprehensive chimney assessment, our typical report includes:

  • Inspection summary
  • Inspection findings with photos and narrative
  • Recommendations for non-outage and outage required repair and maintenance

Enhanced Inspection Services

PULLMAN now offers enhanced chimney inspections – a safe, rapid approach that provides full coverage visual inspections. Utilizing advanced cameras mounted to unmanned aerial vehicles or tethered, our team can provide rapid, total assessment of chimneys and stacks.

The data acquired allows our chimney experts to analyze the entire chimney structure and provide a full report, and to monitor specific conditions and identified issues on future inspections. Additionally, our team builds a digital model of the chimney which may be used to precisely identify locations and tests to perform additional if a more thorough, manned investigation is required.

Repair & Maintenance Programs for Existing Chimneys

Our team designs and implements efficient solutions to fix identified problems, improve safety or extend the service life of chimney and stack components, including:

Liner Upgrades & Replacement

Many chimneys, ducts and flue gas path systems were not designed to meet today’s operating conditions or stringent safety requirements. Upgrades or alterations to the liner systems can help meet these changing demands. Our team partners with owners, builders and designers of unit and plant modifications to work through all project details, including:

  • Liner system selection – our vast experience with all liner system types including brick, gunite, steel, alloy steel and fiber reinforced polymer (FRP) systems helps owners choose the best system for their unique needs.
  • Planning and design – our design and construction teams integrate to develop detailed means and methods for quality control of the liner system as well as designing and fabricating engineered access and work platforms.

Ductwork Alterations & Replacement

As new units are added to existing facilities, PULLMAN provides comprehensive design-build delivery of new ductwork systems.

Our team address the complexities of working in operational facilities and incorporate all project aspects into our designs, including:

  • Ductwork design and fabrication
  • Chimney modifications and tie-ins
  • Construction planning
concrete repair services

Support Infrastructure

PULLMAN designs, builds, repairs and maintains a wide variety of civil infrastructure for flue gas path systems, including:

  • Ductwork support structures
  • Rotating equipment foundations
  • Pedestals and structural supports
  • Tanks and vessels
  • Silos
concrete repair services

Maintenance Planning

Our team designs efficient solutions to fix identified problems, improve safety or extend the service life of chimney and stack components, including:

  • Brick, Alloy, Steel, & FRP Liners
  • Platforms and Ladders
  • Rain Hood
  • Lightning Protection
  • Aviation Warning Lights / Paint
  • Exterior Repairs
  • Coatings
  • Foundations
  • Expansion Joints
  • Ductwork

Decommissioning

Chimneys and stacks that are no longer in service require ongoing maintenance programs to ensure they don’t become a hazard to safety and plant operations. In addition to regular inspections and repairs, our team offers long-term planning and modifications to chimneys and stacks removed from service, including:

  • Exterior repairs and coatings
  • Design, fabrication and installation of chimney capping systems
  • Liner removal
  • Ductwork capping
  • Removal of components

Our Commitment to Safety & Preplanning

Throughout our history, PULLMAN has been the leading designer and builder of reinforced concrete chimneys, stacks, building cores, observation towers, silos, and more. Whether you are building a new structure, or planning to modify or repair an existing one, PULLMAN’s track record and experience provides you with a reliable source for turnkey engineering and construction services.

PULLMAN’s project management and field personnel carefully preplan every project. Our crews address all areas of concern during project pre-planning, including safety, constructability, budgeting, scheduling, and phasing as it relates to optimizing efficiency and potential disruption to ongoing operations.

PULLMAN crews have the manpower to complete projects under the tightest schedules or adjust and phase work to create work schedules that minimize disruption.