WO2011018740A1

WO2011018740A1 - Lintel

Info

Publication number: WO2011018740A1
Application number: PCT/IB2010/053560
Authority: WO
Inventors: Gary Beresforde
Original assignee: Diversity Group Ltd
Priority date: 2009-08-12
Filing date: 2010-08-05
Publication date: 2011-02-17
Also published as: GB2472667B; GB0914091D0; GB2472667A; EP2464800A1; GB201007978D0; WO2011018740A4

Abstract

An L-shaped lintel (102) is described which is braced so that masonry work above the lintel (102) is supported whilst the masonry work underneath is removed to form a window, doorway, arch, etc. The braces (112) enable the masonry work above the lintel (102) to be supported by the L-shaped lintel (102). The lintel has a region of L-shaped cross-section having a substantially horizontal leg and a substantially vertical leg (106). It also has end regions (108, 110) extending vertically away from the vertical leg (106)and braces (112) attached between each end region (108, 110) and an intervening portion (111) or portions of the lintel (102). Also disclosed is a method for making an opening in a wall using the lintel (102).

Description

Title of Invention: LINTEL

Field of Invention

[1] This invention relates to lintels designed for load- supporting and as building aids, in particular to lintels having a region of L-shaped cross section, and most particularly to such a lintel which is braced so that masonry work above the lintel is supported.

Background of the Invention

[2] A lintel is a load-bearing member placed over an opening in a wall such as for

example an entranceway, a window, an archway, etc.

[3] Lintels are well known to the building trade.

[4] If it is desired to make a new opening in an existing wall, for example when building an extension, there is a need to 'knock through' the existing wall. The masonry work above the opening needs to be supported whilst the opening is created. This is particularly important where the wall is a load-bearing wall. Usually this means the builder or the DIYer has to knock a few bricks out to create a hole which then allows the wall above to be supported by an adjustable 'prop'. Typically this is done by making holes through the wall from one side to the other through which metal or wooden poles may be placed, which in turn are supported by a suitable prop - this is a skilled, difficult and lengthy process but has to be done properly to prevent the building collapsing. Once the masonry above the proposed hole is supported, a space is created for insertion of a suitable RSJ or lintel, and then the hole in the wall may be created by removing the masonry. Whilst this long process is taking place, the existing building is open to the elements and not secure.

[5] A slot is cut in the mortar from between courses of masonry above the hole to be created, and the horizontal leg of a typical L-shaped lintel is slid into this space so that masonry work above the lintel is supported in a temporary fashion whilst the masonry work underneath is removed to form a window prior to installation of a permanent lintel.

[6] This approach is somewhat risky because an L-shaped lintel is insufficiently strong to support the masonry work above it, which could lead to the collapse of the wall.

Disclosure of Invention

[7] The present invention addresses the problem associated with an L-shaped lintel being insufficiently strong to support the masonry work above it by providing an L-shaped lintel which is braced so that masonry work above the lintel is supported whilst the masonry work underneath is removed to form a window, doorway, arch, etc. The braces enable the masonry work above the lintel to be supported by the L-shaped lintel. [8] According to various embodiments, but not necessarily all, the present invention provides a lintel comprising a region having an L-shaped cross section, and having a first leg (104) and a second leg (106). End regions extending from the second leg and diagonal braces (112) are attached between each end region and an intervening region

(110) of the lintel so that the lintel is braced to carry masonry above it.

[9] The lintel can include a further horizontal brace attached between the two end

regions. The lintel can be for temporary use to support masonry work above the it whilst the masonry work beneath may be safely removed prior to inserting a permanent lintel or RSJ.

[10] The present invention also provides a method for creating an opening in a wall

comprising the steps of: (a) clearing mortar between two adjacent courses of masonry above where the opening is to be made to create a slot; (b) positioning a horizontal leg of a lintel in the slot and pushing the lintel into a position where it abuts the wall; and (c) removing the masonry beneath the lintel thereby creating the opening. The lintel comprises: (a) a region having an L-shaped cross section having a first leg which, in use is substantially horizontal and a second leg, which, in use is substantially vertical; (b) end regions extending vertically away from the second leg; and (3) diagonal braces (112) attached between each end region and an intervening portion or portions of the lintel.

[11] The diagonal braces can be adjustable tension rods and the method additionally

comprises the step of tightening the braces to prevent any movement of the masonry above the lintel.

[12] The method can additionally comprise the steps of: (a) positioning a permanent lintel or RSJ beneath the lintel; (b) inserting packing material into slots along the horizontal leg so that the packing material is between the masonry work and the permanent lintel or RSJ; (c) removing the lintel.

[13] The present invention also provides a kit comprising: (a) a lintel having: a region having an L-shaped cross section having a first leg which, in use is substantially horizontal and a second leg, which, in use is substantially vertical; end regions extending vertically away from the second leg; and (b) diagonal braces for attaching between each end region and an intervening portion or portions of the lintel.

Brief Description of Drawings

[14] For a more complete explanation of the present invention and the technical advantages thereof, reference is now made to the following description and the accompanying drawing in which:

[15] Figure Ia is a diagrammatic representation of an embodiment of the lintel of the present invention in side view; [16] Figure Ib is a diagrammatic representation of an embodiment of the lintel of the present invention having a pair of diagonal braces;

[17] Figure 2 shows an embodiment of the lintel of the present invention in position in a wall;

[18] Figure 3a is a diagrammatic representation of an embodiment of the lintel of the

present invention in side view;

[19] Figure 3b is a diagrammatic representation of an embodiment of the lintel of the present invention having a pair of diagonal braces;

[20] Figure 4 is a diagrammatic representation of an embodiment of the lintel of the

present invention having two pairs of diagonal braces;

[21] Figure 5a and 5b are diagrammatic representations of embodiments of the lintel of the present invention having a horizontal brace;

[22] Figure 6a is a diagrammatic representation of an embodiment of the lintel of the

present invention having support handles;

[23] Figure 6b a diagrammatic representation of an embodiment of the lintel of the present invention having support handles in side view; and

[24] Figures 7, 8 and 9 show schematics for a lintel of the present invention in which the dimensions are given in mm.

Best Mode for Carrying Out the Invention

[25] Embodiments of the present invention and their technical advantages may be better understood by referring to Figure 1.

[26] Figure Ia is a diagrammatic representation of a section of a lintel (102) having an L- shaped cross section comprising a first leg (104) which, in use is substantially horizontal, a second leg (106), which, in use is substantially vertical, and an end region (108) extending away from the second leg. The first leg of the lintel is able to fit between two courses of masonry in a wall and the second leg of the lintel and the end region abut the masonry. The end region is thus coplanar with the second leg and extends in a direction orthogonal to the first leg.

[27] Figure Ib is the same representation in elevation view, and two end regions

(108,110) are shown. A distance between the end regions is comparable to the size of the opening to be made in the wall. The end regions have anchor points (120) for braces (112), which connect between each end region and corresponding anchor points in an intervening region (111) of the lintel between the end regions. The corresponding anchor points can be located in a centre of the intervening region. In an embodiment for low load applications, the braces comprise wires and turnbuckles to add tension to the support inserted into the masonry, as shown in Figure 2.

[28] In Figures Ia and b, the end regions are shown as extending vertically upwards, but to allow the lintel to be used/inserted in close proximity to soffits/roofs an alternative arrangement is possible, in which the end regions extend vertically downwards, as shown in Figures 3 a and b. It is to be noted that in the arrangement shown in Figures Ia and b, the braces are under compression, whereas in the arrangement shown in Figures 3a and b, the braces are under tension.

[29] In Figure 1, two diagonal braces are shown, but to provide additional support several pairs of diagonal braces (112) can be used to support the L-shaped section of the lintel, as shown in Figure 4.

[30] Alternatively or additionally, a cross brace (114) is attached between anchor points on end regions as shown in Figure 5 a. The alternative arrangement, in which the end regions extend vertically upwards, is shown in Figure 5b. Several pairs of diagonal braces can be used, as described above in relation to Figure 4.

[31] The braces comprising wires and turnbuckles to add tension to the support inserted into the masonry, as shown in Figure 2, do not provide sufficient strength/rigidity for higher loads, such as found in load-bearing walls or for supporting masonry above wide openings. For these applications diagonal braces (112) and horizontal brace (114) comprise threaded bars to tighten and provide the strength/rigidity to support the masonry above the lintel once inserted into a wall. Where the end regions extend vertically downwards (as shown in Figures 3a, 3b and 5b), the braces are under compression and a more robust structure than that provided by the threaded bar is required. For this, the horizontal brace can be a metal plate or angle iron fixed between the end regions in order to meet the requirements of BS5997 part 1. Higher loadings can be achieved using a box section between the end regions. To improve the strength of the lintel, a box section can also be attached to the second leg of the lintel.

[32] For ease of use, any of the embodiments disclosed in the foregoing may have handles

(116) arranged on the end regions of the lintel to assist in positioning. These may be placed conveniently as shown in Figures 5 a and b, allowing the lintel to be lifted up against the wall. A simple handle design is shown in Figure 5b to illustrate how the present invention is enabled, but any suitably shaped handle may be utilized. The handles can also be located on the intervening region of the lintel.

[33] For some applications, for example for smaller openings, horizontal brace (114) will not be required, and fixed diagonal braces (112) rather than adjustable braces that require tensioning can be utilised, as shown in Figures 6a and b.

[34] To improve the safety of the lintel in use, a number of holes (122) are provided in each of the end regions to allow it to be bolted to a wall. There are a number of holes so that at least one can be found to line up with a mortar bed for easy fixing and avoidance of damage to brickwork.

[35] In use, creating an opening in a wall comprises a number of steps. First, mortar between two adjacent courses of masonry above where the opening is to be made is removed to create a slot. This may conveniently be done by cutting into one mortar bed of the existing wall using, for example, an angle grinder. Secondly, the horizontal leg (106) of the lintel is placed in the slot and the lintel pushed into position so that it abuts the wall. Thirdly, if the lintel is fitted with adjustable tension rods these are now tightened to prevent any movement of the masonry above the lintel. The instructions for use will include guidance on the tension to be applied by the user. The end regions, or flanges, at either side are outside the area for removing masonry and the diagonal and horizontal bracing bars do not stop the masonry behind them from being removed, there is more than enough space to work round. Fourthly, the masonry underneath the lintel is knocked out to form an opening. Thus the temporary support lintel does away with several 'aero props' which are cumbersome to put in place and block the opening created restricting access.

[36] The lintel shown in Figures 3a, 3b, 4, 5a, 6a and 6b is appropriate for use where there is limited clearance between the intended positioning of a lintel and a ceiling or soffit above. The lintel shown in Figures Ia, Ib, 2 and 5b requires clearance between the intended positioning of the lintel and a ceiling or soffit above, which can be of the order of 0.5m, it has no restrictions beneath because the tension bars are positioned above the horizontal, supporting lintel. This allows a permanent lintel of any specification, including dual skin Catnik lintels and stone lintels of non-standard sizes, to be inserted into an opening with ease.

[37] A lintel for low load applications, such as the embodiment shown in Figure 2, can be left in place and if necessary fitted with a cavity tray to deflect moisture that transfers across the outer skin of brick work back out. It may then be covered with an internal finish.

[38] In theory the lintel for high load applications could be also left in place, it should have sufficient strength. In practice it would be removed as it is not aesthetically pleasing and would be an eyesore sitting on the outside of the masonry work. To allow the lintel to be easily removed, once the permanent lintel or RSJ has been inserted in place, the bottom edge of the lintel inserted into the cut out mortar has gaps (118) (shown in Figure 7, see below) to allow packing to be inserted between the masonry work and the permanent lintel or RSJ so that the lintel of the present invention may be removed.

[39] The lintel could be used for purposes other than knocking through/installing a

window, door or patio door. It can be used when a device is needed to support a load in a wall. For example, the lintel could be used for damage repair, decorative purposes (eg. replacing a standard wall with a feature wall or installing a feature fireplace), or gaining access to service pipes passing under masonry constructions. [40] The lintel of the present invention can be supplied to the user as a single item having the braces already in place, or it can be supplied as a kit of parts comprising the lintel with separate braces and fixings.

Example 1

[41] An example lintel including an L-shaped 60x60x6 equal angle region of length 1.8m is shown in Figure 7. The lintel includes two threaded diagonal bars (112) and one horizontal threaded bar (114), each having nuts attached to anchors (120) to tension the temporary support lintel and bend the angle iron, thus supporting the masonry work above. Handles (116) are positioned on each end region (108,110) and on the intervening region (111). The lintel shown is of the type exemplified in Figures 3a, 3b, 4, 5a, 6a and 6b and is appropriate for use where there is limited clearance between the intended positioning of a lintel and a ceiling or soffit above. Holes (122) are shown for fixing the lintel in place during use.

Example 2

[42] An example lintel including an L-shaped 60x60x6 equal angle region of length 1.8m is shown in Figure 8. The lintel includes two threaded diagonal bars (112) each having nuts attached to anchors (120). The horizontal brace (114) is provided by 50x50x5 angle iron. The lintel acts under compression to support the lintel and the masonry work above and is of the type exemplified in Figures Ia, Ib, 2 and 5b. It requires clearance between the intended positioning of the lintel and a ceiling or soffit above. Holes (122) are shown for fixing the lintel in place during use.

Example 3

[43] An example lintel including an L-shaped 60x60x6 equal angle region of length 1.8m strengthened by a 60x60x4 box section is shown in Figure 9. The lintel includes two threaded diagonal bars (112) each having nuts attached to anchors (120). The horizontal brace (114) is provided by 50x50x5 angle iron. The lintel acts under compression to support the lintel and the masonry work above and is of the type exemplified in Figures Ia, Ib, 2 and 5b. It requires clearance between the intended positioning of the lintel and a ceiling or soffit above. Holes (122) are shown for fixing the lintel in place during use.

Claims

[Claim 1] A lintel (102) comprising a region having an L-shaped cross section having a first leg (104) and a second leg (106); characterized by the lintel including:

(a) end regions (108,110) extending from the second leg;

(b) an intervening region (111) between the end regions; and

(c) diagonal braces (112) attached between each end region and the intervening region of the lintel.

[Claim 2] The lintel of claim 1 additionally comprising a horizontal brace (114) attached between the end regions.

[Claim 3] The lintel of claim 1 or 2 in which the horizontal brace and/or diagonal braces are adjustable.

[Claim 4] The lintel of claim 1 or 2 in which the horizontal brace and/or diagonal braces include wires and turnbuckles.

[Claim 5] The lintel of claim 1 or 2 in which the horizontal brace and/or diagonal braces include threaded bars.

[Claim 6] The lintel of claim 1 or 2 in which the horizontal brace and/or diagonal braces include a metal plate.

[Claim 7] The lintel of claim 1 or 2 in which the horizontal brace and/or diagonal braces include an angle iron.

[Claim 8] The lintel of claim 1 or 2 in which the horizontal brace and/or diagonal braces include a box section.

[Claim 9] The lintel of claim 1 or 2 in which the second leg includes a metal plate.

[Claim 10] The lintel of claim 1 or 2 in which the second leg includes an angle iron.

[Claim 11] The lintel of claim 1 or 2 in which the second leg includes a box

section.

[Claim 12] The lintel of any of the preceding claims in which the first leg (104) of the lintel is able to fit between two courses of masonry in a wall.

[Claim 13] The lintel of any of the preceding claims in which the second leg of the lintel abuts a wall.

[Claim 14] The lintel of any of the preceding claims in which the end regions abut a wall.

[Claim 15] The lintel of any of the preceding claims in which the end region is coplanar with the second leg and extends in a direction orthogonal to the first leg.

[Claim 16] The lintel of any of the preceding claims in which a distance between the end regions (108) is comparable to a size of an opening to be made in a wall.

[Claim 17] The lintel of any of the preceding claims including handles (116).

[Claim 18] The lintel of claim 17 in which the handles are located on the end

regions.

[Claim 19] The lintel of claim 17 or 18 in which the handles are located on the second leg.

[Claim 20] The lintel of any of the preceding claims having slots (118) in the first leg (106) of the lintel to allow packing material to be inserted.

[Claim 21] The lintel of any of the preceding claims for temporary use.

[Claim 22] The lintel of any of the preceding claims in which the end regions extend vertically upwards when the lintel is in use.

[Claim 23] The lintel of any of claims 1-22 in which the end regions extend

vertically downwards when the lintel is in use.

[Claim 24] The lintel of any of the preceding claims in which the end regions include holes for fixing the lintel securely in place to a wall.

[Claim 25] A method for creating an opening in a wall comprising the steps of:

(a) clearing mortar between two adjacent courses of masonry above where the opening is to be made to create a slot ;

(b) positioning a horizontal leg (104) of a lintel (102) in the slot and pushing the lintel into a position where it abuts the wall, said lintel comprising:

(1) a region having an L-shaped cross section having a first leg (104) which, in use is substantially horizontal and a second leg (106), which, in use is substantially vertical;

(2) end regions (108) extending vertically away from the second leg; and

(3) diagonal braces (112) attached between each end region and an intervening portion or portions of the lintel; and

(c) removing the masonry beneath the lintel thereby creating the opening.

[Claim 26] The method of claim 25 in which the diagonal braces are adjustable tension rods additionally comprising the step of tightening the braces to prevent any movement of the masonry above the lintel.

[Claim 27] The method of claim 25 additionally comprising the steps of:

(a) positioning a permanent lintel or RSJ beneath the lintel (102);

(b) inserting packing material into slots (118) along the horizontal leg (106) so that the packing material is between the masonry work and the permanent lintel or RSJ;

(c) removing lintel (102).

[Claim 28] A kit comprising:

(a) a lintel having:

(1) a region having an L-shaped cross section having a first leg (104) and a second leg (106);

(2) end regions (108) extending from the second leg;

(3) an intervening region (110) between the end regions;

(b) diagonal braces (112) for attaching between each end region and the intervening region (110) of the lintel.

[Claim 29] 29. The kit of claim 28 wherein said braces are adjustable and additionally comprising instructions on the tension to be applied to the lintel by the user.