4 Simple Steps for Hassle-Free Lintel Installation and Bricking Up * bigfinish.com

Before you can begin installing a pre-stressed lintel and bricking up, you need to make sure you have the right materials and tools. You will need a pre-stressed lintel, a bricklayer’s trowel, a level, a plumb bob, a tape measure, a hammer, and some nails. In addition, you may also want to wear safety glasses and gloves.

Once you have gathered your materials and prepared your workspace, you can begin installing the pre-stressed lintel. First, you need to find the center of the opening where you will be installing the lintel. Then, you need to align the lintel with the center of the opening. Once the lintel is in place, you can secure it with nails or bolts. Finally, you can begin bricking up the opening around the lintel. To do this, you will need to use a bricklayer’s trowel to apply mortar to the bricks. Once the bricks are in place, you can use a level and plumb bob to make sure they are level and plumb. After the bricks are dry, you can finish the job by pointing the joints between the bricks.

Installing a pre-stressed lintel and bricking up is a relatively simple task that can be completed in a few hours. However, it is important to take your time and do the job correctly. If you do not, you could end up with a cracked lintel or a wall that is not level. By following the instructions in this article, you can ensure that your lintel is installed correctly and that your wall is structurally sound.

Preparing the Lintel

Proper preparation of the lintel ensures its structural integrity and longevity. Follow these steps meticulously:

1. Choose the Appropriate Lintel

Select a pre-stressed concrete lintel that meets the specific load requirements and span distance of the opening. Consider factors such as imposed loads, bearing capacity, and building codes. Consult with a qualified engineer for complex or high-load applications.

Lintel Type	Loading Capacity	Span Distance
Single-Beam Lintel	Medium to Heavy	Up to 10 feet
Double-Beam Lintel	Heavy	Over 10 feet
Box Beam Lintel	Very Heavy	Customizable

2. Position the Bearing Surfaces

Prepare the bearing surfaces where the lintel will rest on the walls. Ensure that they are level, plumb, and of sufficient strength to support the load. Remove any loose or uneven material, and create a bed joint with mortar to ensure a solid bond.

3. Install the Lintel

Use a crane or other appropriate lifting equipment to position the lintel over the opening. Carefully align it with the bearing surfaces and lower it into place. Ensure that the lintel is centered in the opening and sits level.

Installing the Lintel

Pre-stressed lintels are designed to support the weight of the brickwork above them. They are typically made of concrete and are reinforced with steel bars. Pre-stressed lintels are available in a variety of sizes and shapes, so it is important to choose the correct size for your application.

To install a pre-stressed lintel, you will need the following tools and materials:

Pre-stressed lintel
Mortar
Trowel
Level
Hammer
Chisel

Once you have gathered your tools and materials, you can begin the installation process.

Start by preparing the area where the lintel will be installed. This involves removing any existing brickwork and cleaning the surface of the wall.
Next, position the lintel in the opening. Use a level to make sure that the lintel is level, and then use a hammer and chisel to chip away any excess mortar from the edges of the lintel.
Apply a thick bead of mortar to the top and bottom of the lintel. Then, use a trowel to spread the mortar evenly over the surface of the lintel.
Place the bricks on top of the lintel, and use a trowel to spread mortar between the bricks. Continue adding bricks until the opening is completely filled.

Here are some additional tips for installing a pre-stressed lintel:

Make sure that the lintel is strong enough to support the weight of the brickwork above it.
Install the lintel level to ensure that the brickwork is stable.
Use a thick bead of mortar to seal the gaps between the lintel and the brickwork.

Tool	Description
Trowel	Used to spread mortar
Level	Used to make sure the lintel is level
Hammer	Used to chip away excess mortar
Chisel	Used to chip away excess mortar

Creating the Formwork

To install a pre-stressed lintel and brick it up, you’ll need to start by creating the formwork. The formwork is the temporary structure that will hold the lintel in place while the mortar sets. It’s important to build the formwork carefully, as any mistakes could compromise the integrity of the lintel installation.

Step 1: Determine the Lintel Size and Location

Before you start building the formwork, you need to determine the size and location of the lintel. The size of the lintel will depend on the span of the opening that you’re bridging, and the location will depend on the height of the opening and the level of the surrounding masonry.

Step 2: Build the Formwork

Once you know the size and location of the lintel, you can start building the formwork. The formwork is typically made from timber, and it should be strong enough to support the weight of the lintel and the masonry that will be placed on top of it.

Step 3: Install the Lintel

Once the formwork is complete, you can install the lintel. The lintel should be placed in the center of the opening, and it should be level and plumb. Once the lintel is in place, you can start bricking it up.

Materials	Quantity
Timber	Varies depending on the size of the opening
Nails or screws	Varies depending on the size of the opening
Level	1
Plumb	1

Mixing and Pouring the Mortar

Preparation

Before mixing the mortar, gather the necessary materials: lime, sand, cement, water, and a mixing trough or wheelbarrow. Determine the appropriate proportions for your project, as they vary depending on the type of mortar you’re using.

To ensure a uniform mix, start by placing the sand and cement in the trough. Gradually add water while mixing thoroughly with a hoe or shovel. The consistency of the mortar should be similar to thick paste; adjust the water content as needed. Avoid adding too much water, as this can weaken the mortar.

Pouring the Mortar

Once the mortar is mixed, you can begin pouring it into the pre-stressed lintel. Use a trowel or bricklayer’s spoon to carefully fill the cavity between the bricks. Press the mortar firmly into place, ensuring it fills all gaps and bonds with the bricks.

Leveling the Mortar

Using a spirit level, check the level of the mortar as you pour it. Make adjustments as necessary by adding or removing mortar until it is level both horizontally and vertically. This will ensure the lintel provides adequate support and maintains a uniform appearance.

Finishing the Mortar

Once the mortar is poured and leveled, use a pointing trowel to smooth out the surface. This will remove any excess mortar and create a clean and professional-looking finish. Allow the mortar to cure for the recommended time before applying any additional weight or load to the lintel.

Setting the Bricks

Setting the bricks for a brick up is a crucial step that requires precision and attention to detail.

Prepare the Mortar: Mix the mortar according to the manufacturer’s instructions. It should be of a workable consistency, not too stiff or too runny.
Butter the Bricks: Apply a layer of mortar to the face of the brick that will be exposed. This will help the brick adhere to the wall.
Lay the First Course: Start by laying the first course of bricks on the prepared base. Ensure they are level and aligned. Use a string line or laser level for guidance.
Build the Courses: Continue stacking the bricks in courses, buttering each brick before placing it. Interlock the bricks by alternating their orientation (header and stretcher courses).
Check Alignment and Level: Regularly check the alignment and level of the wall using a spirit level. Adjust the bricks as needed to ensure a straight and even surface.
Fill the Joints: As you build the wall, fill the joints between the bricks with mortar using a pointing trowel. Push the mortar into the joints firmly to create a solid bond.
Strike the Joints: Once the mortar has slightly set, strike the joints to smooth them out and create a professional finish. Use a jointing tool or a piece of wood to achieve the desired joint shape.
Clean the Surface: Use a damp sponge or brush to remove any excess mortar or debris from the face of the bricks. This will ensure a clean and aesthetically pleasing finish.
Cure the Mortar: Allow the mortar to cure properly by following the manufacturer’s recommendations. This may take several days or weeks, depending on the type of mortar used.

Brick Up Lintel Table

Grouting the Bricks

Before starting the grouting process, gather the necessary materials, which include mortar mix, a bucket, a trowel, a pointing gun, and a sponge. Follow these detailed steps to ensure a successful grouting job:

Prepare the Mortar Mix: Mix the mortar according to the manufacturer’s instructions to achieve a thick, workable consistency.
Apply Mortar to Horizontal Joints: Use the trowel to apply a generous amount of mortar to the horizontal joints between the bricks. Smooth the mortar firmly into the gaps to create a solid seal.
Fill Vertical Joints: Switch to the pointing gun and fill the vertical joints between the bricks. Squeeze the mortar into the joints until they are completely filled. Use your finger or a tool to smooth the mortar and remove any excess.
Compact the Mortar: Once the joints are filled, compact the mortar by pressing it firmly with a trowel or a compacting tool. This will ensure a strong and durable bond.
Strike the Excess Mortar: Use the trowel to strike off any excess mortar that is protruding from the joints. Aim for a flush finish with the brick surface.

Tooling the Joints: This step gives the joints a clean and professional look. Select a suitable joint tooling tool, such as a concave or convex jointer, and run it along the joints to shape them.

Remember to keep the sponge handy to clean up any mortar smudges or excess while grouting. Allow the mortar to cure according to the manufacturer’s specifications before exposing it to heavy loads or moisture.

Striking the Formwork

1. Wait for the Mortar to Cure

Allow the mortar to cure for at least 24 hours before removing the formwork.

2. Check the Lintel for Deflection

Inspect the lintel for any deflection. If there is significant deflection, wait longer for the mortar to cure.

3. Remove the Temporary Supports

Remove the temporary supports that were holding up the lintel.

4. Tap on the Formwork with a Hammer

Tap on the formwork with a hammer to loosen it. Do not use excessive force.

5. Pry the Formwork Away

Use a pry bar to gently pry the formwork away from the lintel. Start at one end and work your way along the length of the lintel.

6. Clean the Lintel

Clean the lintel of any mortar or debris.

7. Brick Up the Opening

Once the lintel is in place, you can brick up the opening. Follow these steps:

Step	Instructions
1	Lay a course of bricks on top of the lintel.
2	Spread a layer of mortar on the top of the bricks.
3	Lay another course of bricks on top of the mortar.
4	Continue laying bricks in this manner until the opening is filled.
5	Point the joints between the bricks with mortar.

Finalizing the Installation

8. Grouting and Pointing

After the brickwork has set, fill the joints between the bricks and the lintel with mortar. Use a pointing trowel to smooth the mortar and create a neat finish. To ensure a watertight seal, apply a waterproof sealant to the joints.

To protect the lintel from corrosion, apply a rust-resistant primer and paint. This will extend the life of the lintel and maintain its structural integrity.

Finally, remove any excess mortar from the surrounding area and clean the lintel and brickwork. Inspect the installation for any imperfections and make necessary adjustments to ensure a professional-looking finish.

Safety Precautions

When working with pre-stressed lintels and bricks, it is essential to prioritize safety. Follow these precautions to minimize risks:

1. Wear Protective Gear

Don safety glasses, gloves, and a hard hat to safeguard your eyes, hands, and head.

2. Inspect Materials

Examine the lintel and bricks for any damage or defects before installation. Damaged materials can compromise structural integrity.

3. Use Proper Lifting Techniques

Pre-stressed lintels are heavy. Employ proper lifting techniques to prevent back injuries and accidents.

4. Ensure Stable Footing

Work on a level and stable surface to prevent slips or falls while handling materials.

5. Barricade the Area

Secure the work area to prevent access by unauthorized personnel or children who could be at risk.

6. Use Appropriate Tools

Utilize the correct tools for the job, such as a level, trowel, and mortar mixer, to ensure accurate installation.

7. Follow Building Regulations

Adhere to local building codes and regulations regarding lintel and brickwork installation to ensure structural compliance.

8. Seek Professional Assistance If Needed

If you lack experience or encounter difficulties, don’t hesitate to seek guidance from a qualified professional.

9. Lintel and Brickwork Inspection

Thoroughly inspect the installed lintel and brickwork upon completion. Check for:

– Proper alignment of the lintel

– Level and plumb brickwork

– Solid mortar joints

– Absence of cracks or damage

Troubleshooting Common Issues

1. Uneven Support for Beam

Ensure the beam is adequately supported throughout its span. Insufficient support can lead to sagging and bending, compromising the lintel’s integrity.

2. Improper Anchorage

Verify that the beam is properly anchored into the adjacent masonry. Insufficient anchorage can cause the lintel to shift or fail under load.

3. Overload

Assess whether the beam is being subjected to an excessive load. Overloading can result in cracking, bending, or collapse of the lintel.

4. Thermal Expansion

Consider the effects of thermal expansion on the beam. Extreme temperature changes can cause the beam to expand or contract, potentially leading to movement or cracking.

5. Moisture Intrusion

Protect the beam from moisture penetration. Exposure to water can cause corrosion, weakening the beam over time.

6. Deflection

Monitor the beam for excessive deflection. Significant deflection can indicate structural issues or an undersized beam.

7. Cracking

Investigate any cracks in the beam. Hairline cracks may be normal, but larger or more extensive cracks require professional assessment.

8. Rusting

Address any rusting on the beam. Rust can weaken the metal, compromising the lintel’s capacity.

9. Loose or Missing Bolts

Check for loose or missing bolts securing the beam to the supporting structure. Tighten or replace bolts as necessary.

10. Inadequate Masonry Support

Verify that the surrounding masonry is strong enough to support the lintel and its load. Weak masonry can lead to settlement or cracking of the lintel.

How To: Install Pre-Stressed Lintel And Brick Up

Installing a pre-stressed lintel and bricking it up is a relatively straightforward process, but it is important to follow the steps carefully to ensure a successful installation.

Step 1: Install the Lintel

The first step is to install the pre-stressed lintel. This is typically done by placing the lintel on the wall and securing it with bolts or other fasteners.

Step 2: Brick Up the Lintel

Once the lintel is installed, the next step is to brick it up. This is done by laying bricks around the lintel, starting at the bottom and working your way up.

Step 3: Finish the Brickwork

Once the bricks are in place, the final step is to finish the brickwork. This can be done by pointing the joints between the bricks and cleaning the surface of the brickwork.