​40 years of innovation in Chimney Camera Inspection Systems
Over twenty years ago, Jim Gillam of SNEWs wrote a great article about Estoban Corporation, the manufacturer of Chim-Scan® Chimney Camera Systems for internal chimney inspections. Another article was featured in Blue Collar Magazine in 2021. Now, it is time to bring you up to date in 2024.

Many assume that Estoban's location is in some big glass building with a giant loading dock. This mental image could not be farther from the truth; 99.5% of people driving by Estoban do not even know we are here. We are located outside a small town called Fairfield in southeast Iowa. If you google Fairfield, Iowa, you'll get some fun articles, videos, and even an Oprah visit.
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Estoban isn't a spelling error; it's the combination of Owners' names. E stands for Esther, S stands for Shelley, TO stands for Tom, and BAN stands for Urban. Mom and Pop, who revolutionized the industry, still run the business. Jim's article is a great way to know how Estoban started. So, here's a link to Jim's article; please read it. 

In a brief overview, Tom and Esther started as chimney sweeps in the late '70s; as time passed, Tom's curiosity and concern for his customers' homes got the better of him. Like all sweeps, customers asked him, 'Is the chimney safe?' He couldn't wholeheartedly answer because he knew he didn't see everything.
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Tom started tinkering. He traveled to Cornell University to search the library's optics section of Thomas Registers. A year later, Tom built the Footlocker Camera, which was lovingly named because it was the size of a footlocker with a lens.

In 1984, at the National Chimney Sweep Guild convention in Washington, D.C., Chim-Scan® was shown for the first time to a national audience. CNN News Channel pronounced it a showstopper, and many thought Tom was nuts for sticking a camera in a chimney, but time has shown he's an innovator.

So, in the early 2000s, Chim-Scan® built units that connect to computers, which was AWESOME. Then the World experienced the 'wonderful' (please note sarcasm) jump in Windows Operating systems of XP>Vista>Windows 7>Windows 8> and finally 10. During this jump, they learned the hard way of working with 3rd party parts and programs: one day, they are here, and the next, they're gone.This great inconvenience led them to look for other recording abilities. They have used Polaroid, VHS, Floppy disks, CF burners, PDAs, Computers, DVD recorders, and four versions of SD recorders - all done by 2010.
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Estoban stays current on new technology, but with the rise of disposable technology, they have become even pickier about what they put in their equipment. They only buy and work with commercial electronics, which tend to move slightly slower than consumer electronics. They use Commercial because it has to work day after day, with the option of repair. Shelley explained, "One would never trust a sewer company if they showed up with a teeny tiny camera hooked up to their phone. That stuff is cool and cheap but cannot withstand everyday abuse."
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Back in 2000, when Jim's article came out, Estoban had just added on the schoolroom (where Shelley was homeschooled until high school), a big new office, and the machine room. A total of about 2,000 sq ft: they quickly outgrew that by 2008, they added on Electron row, which now serves as a hallway with 3-D printers, and the 'shipping room,' now the office, added another 800 sq ft. The schoolroom was transformed into Marvin's repair room, bathroom, and commissary. For anyone wondering, Marvin is their oldest employee; he's worked for Estoban for over 30 years, which is why he gets his room. The original shop was now surrounded and became half wiring, half internal highway.

In 2014, we had a record year but at a dreadful cost. From July to January 2015, the company worked seven days a week, sometimes 12 hours a day. This busy schedule was due to disappointing results from high expectations of a cheaper product that came on the market that did not fulfill the vision needs that a Chim-Scan® chimney inspection system can produce. Well, that opened a fantastic door. We heard from people we hadn't spoken to since the mid-'90s, and many jumped on the 'I want to upgrade my old unit' bandwagon.

For those who might not know, Estoban builds Chim-Scan® Units right in Iowa, and we repair, and upgrade units built since 2010. It used to be 1995; however, we had to change to 2010 as new and old technology is a little over 66 units a month, which may sound small, but that number does not include routine repairs or new units, which always work well together. Units were housed in Tom and Esther's front/living room before the busy season repairs came in mid-September. We realized during this time that we needed to expand. As of December 31, we had upgraded over 400 units. When you do that, math bumps the unit number around 800. Eight hundred may seem like a medium-sized number, but to put it into perspective, we don't physically build the monitor, SD recorder, and camera chip. Everything else is built in-house. When you look at a Chim-Scan®, you are looking at a controller that Alicia or Shelley wired, a Case that Tom or other staff built, a reeler that Esther or Therese wired, and a camera that Tom or Shelley built. 

In 2016, the new addition, the backroom, was added. We had a great local team come, and the whole building was constructed, insulated, and concrete poured in 4 days. It was amazing. The Urban Family spent the next two weeks riding bicycles around the 4,000 sq ft addition, waiting for the concrete to cure.
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The new addition starts with a 9-foot ceiling and then jumps to a 16-foot ceiling, allowing us to build a mezzanine. The back half of the 'Backroom' is Tom's Chimney Lab. They have a masonry fireplace, prefab insert, and a masonry thimble chimney; the mezzanine allows roof access to these chimneys just by climbing a set of stairs. Watching their videos, you'll see the Lab; they use it daily to test repairs, new units, and new products. There is also a 14x30 classroom that provides space for training, Zoom meetings, and video presentations.

Tom's favorite tools are his four CNC machines; they have sped up production 100-fold. Parts are constructed in-house for the Chim-Scan® Units. Tom shares these tasks with other employees.

In 2020, Estoban could stay up and running even when other businesses had to close. Tom and Esther literally walk out the door, down a short sidewalk and into the office. Staff was spaced so everyone had their own work area during the pandemic.

As stated before, Estoban also repairs the equipment it builds; this involves the oldest employee, Marvin, who performs most repairs, and Ray, the quality control, shipping, and receiving guy. Every package that comes in gets unpacked and photographed by Ray, who then cleans it within an inch of its life and hands it over to Marvin, who does 80% of the repairs and upgrades. Esther, Alicia, Shelley, and Tom pick up the other 10%. Once a Repair or Upgrade is complete, it gets reviewed, tested, and tested a second time by Ray or whoever is free. It is then cleaned again (as fine soot is worse than glitter to get rid of), photographed, boxed up, and shipped out.

Alicia wires the New Controller/Monitors, and Tom and Steve build the cases for the 211 and make modifications for the 100 Units. Esther or Therese builds the reeler, and Tom or Shelley build the cameras.

Shelley creates CAD drawings and works with 3D printers to create parts for units, which has helped the operation become more efficient.  This frees up the CNC machines to manufacture other parts.

Once new units are complete, they 'sit' for 8 hours, being turned on and off, running for a few minutes to hours, are taken to the Lab, and run up the chimneys to test every part of the unit. They are then photographed, packed, and shipped. You may ask, "What's with all the pictures?" Well, it serves many purposes. The primary objective is that we can see what they're talking about when a customer calls. 

Some may ask, with the listed jobs above, who answers the phone? Shelley and Esther are the voices of Estoban; they cover customer service, sales, and tech support. Shelley is also a webmaster and marketing department.

Estoban also has the benefit of being a pet-friendly workplace. If you stop by for a visit, you receive a greeting from Bella, the Wheaten terrier, and a dismissive glance from Binx, the cat, aka Inspector 13. Bella oversees internal security, employee well-being, and occasional photo shoots. Binx oversees everyone's work, and the rare photoshoot.

Speaking of the past, you may ask, What about the future?
Shelley plans to run Estoban if Tom and Esther ever retire; she will maintain their standard of excellence and keep growing with technology.

When looking up a dark chimney flue with a flashlight, you will see what the light illuminates in degrees of shapes and shadows. Remember, you will also be looking at it from just one angle. Visual acuity (clarity of vision) differs from person to person. It is a rating of a person's ability to recognize small details precisely. Many factors can affect the quality of a person's eyesight, one being brightness. Because you shine a flashlight into a dark chimney flue, similar to looking into a dark tunnel, the details you can gather with the naked eye are minimal. However, a Chim-Scan® Chimney Camera can provide a close view with adjustable lens angles and variable light brightness. This surpasses the naked eye, captures details, and provides images and videos.

Should a flashlight and the naked eye be used to inspect a chimney?
I taught chimney inspection classes for over 21 years and used a prop with hidden defects (the images at the right). Almost 99% of the time, the inspectors missed an opening within the chimney flue using a flashlight and the naked eye. These defects were only 17” from their faces. If a chimney technician inspects a flue with a flashlight and notes there were no defects, they risk opening themselves up for liability or lack of disclosure for missed defects. If the chimney was scanned with a camera the previous year, and no events were noticed, a flashlight may be sufficient for the inspection if you performed a chimney scan inspection the previous year and they didn't use their chimney.

Currently, in the chimney industry, inspections with a flashlight are allowed on a Level 1 Inspection at least once a year, during a routine cleaning of the chimney flue, replacement of a connected appliance with one of a similar type, input rating, and efficiency according to NFPA 211. However, are you really sure you could see everything?

The language in Level 1 (15.3.2.4) asks for verification that the flue or flues are free of combustible deposits and blockage or obstruction. But the language in Chapter 14 of NFPA 211 does state that if the flue liner has softened, cracked, or otherwise deteriorated so that it no longer has the continued ability to contain the products of combustion (i.e., heat, moisture, creosote, and flue gases), the liner shall be either removed and replaced, repaired, or relined with a listed liner system (14.9). Can you determine all of this with a flashlight?

A camera with a tilting lens captures angles and textures and defines the movement of the flue tiles.
The beauty of inspecting chimney flues with an adjustable tilt lens, like the J3D and Lighthouse™ Tilt Cameras, is that changes to the masonry are more apparent when looking at it from different angles. If I look only at the sides of the chimney, I may miss the fact that the flue tiles are severely misaligned. If I look straight down or up the chimney, I will miss openings between the clay flue tiles. I may also miss a hole in a flue hidden by severely misaligned tiles, as the photos show. Instead, when using these tilt lens cameras, I can see how thick a mortar joint is, how much mortar is missing, whether the tile has damage and whether there is a hidden breeching, amongst other defects.
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Illumination is critical to diagnosing defects. What do you see if you look down a chimney with a flashlight? Most likely, you will see shapes, shadows, and lines. It will be up to your brain to form a picture and decide if these shapes, shadows, and lines constitute a defect. How good is your eyesight? How good is your flashlight?

When scanning a chimney with a properly illuminated camera, you can pinpoint defects as small as hairline cracks or degradation. If you look down a chimney and see creosote, can you define it? Is it a dark mass in the flue? Can you tell whether it is glossy, goopy, or tarlike creosote? Or is it shiny – almost reflective when the camera illuminates it head-on? How is the texture - puffy, granular, light soot, tarlike, or glazed? Can you see surface degradation?

Not every chimney camera is the same.
Now that we have described the ideal chimney scanning system, you need to know that not all chimney cameras have a tilt lens and adjustable lighting. Not all lenses can spin in a circle. With some systems, the technician must properly turn the camera while inspecting and videoing the flue. This video often ends up a wobbly mess, which gives the viewer an inclination to car sickness. The quality of the camera and the ability to get clear, focused pictures are essential to finding and diagnosing defects. Unfortunately, a camera with poor images shines a bad light on the technician. If the customer can't see a clear picture of a defect, it's a credibility wrecker.
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In closing
A chimney can be seen as a unique appliance in the home. It is a channel whereby the products of combustions shall pass through and exit the atmosphere. A chimney may also be a part of the fireplace or heater's draft. It must keep the elements out of the home, yet not without closing off the drafting function. It is exposed to heat inside and cold outside. It is exposed to the elements - rain, snow, wind, and weather events. There is no doubt that it is integral to the home. When it comes down to having an inspection and you are a homeowner reading this, demand that the chimney is scanned with a chimney camera. Especially one with quality photos, such as the Chim-Scan® Internal Evaluation Camera System.
If you are a chimney technician, remember to use your camera on every job!

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