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Replacing lead flashing: how it should be done
Chimney
6 min read

Replacing lead flashing: how it should be done

Lead flashing should overlap generously, be worked into a raked-out mortar joint and be cut into pieces short enough to absorb expansion. Lead that is fitted in lengths that are too long cracks at the fold, and that is the most common cause of a leak at a chimney.
Portrait of an Astrodak roofer at work on a roof
Fouad · Owner of Astrodak Service
Updated on 21 August 2026
Brick chimney with a concrete cap and new leadwork on a flat roof with solar panels
Lead stepped along with the rows of tiles and worked into the joint.
Leadwork is the part of a roof where the difference between good and mediocre work shows most clearly, just not straight away. On completion, poor leadwork looks exactly like good leadwork. You notice the difference after year eight.
That is why this is one of the few parts I like to explain properly. Then you can ask about it yourself.

The four rules of good leadwork

1
Generous overlap. Lead that guides water over the tiles has to reach far enough over those tiles. A tight overlap works in normal rain, but not in driving rain that is pushed upwards.
2
Worked into a raked-out joint. The lead should go into the brickwork, in a joint that has been raked out and then refilled. Lead that is only stuck to the wall with sealant comes loose within a few years.
3
Short enough per piece. This is the most important and least known rule. Lead expands with temperature. One long piece cannot absorb that movement and cracks at the fold. That is why you work with shorter pieces that overlap each other.
4
Free to move. Lead that is fixed on two sides is under stress with every change in temperature. One side fixed, the other free.
“The classic mistake is one nice long piece of lead. It looks neat and cracks exactly at the fold eight years later.”
Fouad, owner of Astrodak Service

Where leadwork is found

Around the chimney is the best-known place, but not the only one. At a wall abutment where the roof meets a higher wall, all around a dormer, in the valley gutter where two roof slopes meet, at a roof window and at wall copings.
On a thirty-year-old roof, the lead in all those places is the same age. If one place fails, it is often the first of several, and that is why we also check the other junctions when we repair lead. See valley gutter leaks and leaks at a dormer.
Lead
40 years or more
when properly fitted
Lead under stress
8 to 15
years
Free roof inspection

Not sure about the right approach?

I would rather come and look at your roof with my colleagues first than come up with a solution from a distance. During the free inspection you hear what is really needed, even if that is less than you thought.

What you can see yourself

From a roof window or a safe spot: is the lead lifting anywhere, is there a small crack at the fold, or has the lead come out of the joint with a strip of sealant over it? That last one is usually an earlier emergency repair and means the lead has already failed once.
In the attic: water rings on the roof boarding next to the chimney, or white lime streaks running from top to bottom. See following the water trail.

Lead or an alternative

There are lead substitutes on the market: flexible strips with an aluminium or plastic core that are applied with an adhesive layer. They have advantages, especially in places where lead is hard to fit and for environmental reasons.
For a main chimney junction on a house, I usually still choose lead, because it lasts longer when properly fitted and the material can be dressed better to the shape of the tiles. See lead or a lead substitute and the page on chimney repair.

Why you do not work over old lead

A tempting fix for a leaking flashing is to lay a new strip over the old one, or run a strip of sealant over the fold. That works for a season. The old lead keeps moving underneath, the new layer cracks with it, and the moisture that has got behind it by then cannot escape.
That is why the old lead comes out before new lead goes in. That means lifting tiles, raking out the joint and working the new lead back in with a generous overlap. More work, and it is the only approach that lasts for decades.

Frequently asked questions about leadwork

Because lead expands in the sun and contracts in the cold. A long piece that is fixed on two sides cannot absorb that movement and will crack at its weakest point, the fold. That is why you work with shorter pieces that overlap each other.

Forty years or more when properly fitted with generous overlaps and enough freedom to move. Lead that is under stress or fitted in lengths that are too long can start cracking after just eight to fifteen years.

It happens, and it comes loose within a few years. Lead should be worked into a raked-out joint that is then refilled. A strip of sealant over the lead is almost always the sign of an earlier emergency repair.

If it is the same age, that is sensible. If one junction fails, the others are usually just as old and will follow within a few years. A second visit means paying for travel and setting up again.

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