STRUCTURAL STEEL LINTEL

Abstract

A structural lintel is similarly shaped as an I-beam having a horizontal lower (or bottom) flange, a horizontal upper (or top) flange and a vertical web extending therebetween. The flanges and the web form spaces, at respective lateral sides of the web. The upper flange is narrower in width than the lower flange. The depth of the lintel is determined by the height of the web. The height of the web is chosen such that the internal depth, being the distance between the facing internal surfaces of the lower flange and the upper flange is equal to:

Number of brick courses (N)*Depth of each brick in mm (D)+(N1)*Mortar Course Thickness in mm (M)

Where N2

Claims

1. A lintel, comprising: a beam structure having a top flange and a bottom flange with a web extending therebetween, the beam having an internal depth extending from an internal surface of the top flange to an internal surface of the bottom flange, the internal depth being equal to the sum of the number of brick courses to be received between the top and bottom flanges multiplied by the depth of a brick, plus the depth of mortar courses between the brick courses.

2. The lintel of claim 1, wherein the top and bottom flanges each have a thickness equal to the depth of a mortar course.

3. The lintel of claim 1, wherein the web has a thickness not greater than the depth of a mortar course.

4. The lintel of claim 1 wherein the top flange is narrower in the width than the bottom flange.

5. The lintel of claim 4 wherein the top flange is offset relative to the web.

6. The lintel of claim 4 wherein the top flange is centrally located relative to the web.

7. The lintel of claim 1 further comprising spaced holes in the web at heights corresponding to the mortar courses.

8. The lintel of claim 1 wherein the width of the bottom flange is less than the sum of the widths of two bricks plus a vertical mortar joint between them.

9. The lintel of claim 1 wherein the top and bottom flanges have a thickness of 10 mm and the web has a thickness no greater than 10 mm.

10. The lintel of claim 1 wherein the bottom flange width is between 200 mm to 210 mm.

11. The lintel of claim 1 further comprising tie-down formations along the top surface of the top flange.

12. The lintel of claim 11 wherein the tie-down formations comprise lugs mounted in a spaced manner along the top surface.

13. The lintel of claim 12 wherein the lugs comprise upside down U-shaped rods with ends thereof mounted by welding to the top surface.

14. The lintel of claim 1 wherein the web is disposed to extend from corresponding aligned side edges of the top flange and the bottom flange.

15. The lintel of claim 14 further comprising spaced holes in the top flange.

16. The lintel of claim 14 wherein the upper and lower flanges have a thickness of 5 mm.

17. The lintel of claim 14 wherein the beam has an external depth extending from an external surface of the top flange to an external surface of the bottom flange, the external depth being equal the sum of the number of brick courses to be received between the top and bottom flanges multiplied by the depth of a brick, plus the number of brick courses multiplied by a mortar course depth, plus the depth of the top flange.

18. An assembly, comprising: a lintel of claim 1; and brick and mortar courses disposed between the internal surfaces.

19. An assembly, comprising: a lintel of claim 17; and brick and mortar courses disposed between the internal surfaces.

20. An assembly, comprising; a lintel of claim 11; and straps fed through the tie-down formations, wherein ends of the straps are attached to a timber plate or a roof truss.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0039] FIG. 1 is a cross-sectional view of a typical T-bar with bricks laid on it.

[0040] FIG. 2 is another sectional view of a typical PFC and plate section showing brickwork and open PFC to the inside of the wall.

[0041] FIG. 3 is a sectional view of a typical PFC and plate with external brickwork and timber wall on top of the PFC and open PFC.

[0042] FIG. 4A is a sectional view of a typical PFC and plate section.

[0043] FIG. 4B is a sectional view of a typical T-bar section.

[0044] FIG. 5 is a cross-sectional view of the proposed lintel of the invention according to a first embodiment with holes in the web for a 3 brick course configuration.

[0045] FIG. 6 is a cross-sectional view of the proposed lintel of the invention according to the first embodiment showing brickwork and the concealed lintel top flange and web.

[0046] FIG. 7 is a partial isometric perspective view of the lintel of the first embodiment showing the equi-spaced holes for a 3 course brick beam.

[0047] FIG. 8 is a partial isometric perspective view of the lintel of the first embodiment showing a typical configuration of a 3 course lintel, with several bricks of the first course laid, with a shear connector bedded in the first hole and a brick tie in the second hole in the first mortar course.

[0048] FIG. 9 is a cross-sectional view of the proposed lintel of the invention according to a second embodiment with a centrally located top flange of lesser width showing brickwork and the concealed lintel top flange and web.

[0049] FIG. 10 is a cross-sectional view of the proposed lintel according to the second embodiment.

[0050] FIG. 11(a) is a cross-sectional view of a prior art structural angle lintel with bricks mounted thereon.

[0051] FIG. 11(b) is a cross-sectional view of a C-section lintel according to another embodiment of the invention with bricks mounted thereon, this embodiment dimensioned to receive one course.

[0052] FIG. 11(c) is a cross-sectional view of a C-section lintel with bricks mounted thereon according to another embodiment.

[0053] FIG. 11(d) is a cross-sectional view.

[0054] FIG. 11(f) is a perspective view of this lintel, this embodiment dimensioned to receive two courses.

[0055] FIG. 11(e) is a cross-sectional view of a C-section lintel with bricks mounted thereon according to another embodiment, this embodiment dimensioned to receive three courses.

[0056] FIG. 12(a) is a cross-sectional view of a lintel with bricks mounted thereon according to another embodiment.

[0057] FIG. 12(b) is a cross-sectional view of this lintel, this embodiment dimensioned to receive two courses.

[0058] FIG. 12(c) is a cross-section of a lintel with bricks mounted thereon according to another embodiment, this embodiment dimensioned to receive three courses,

[0059] FIGS. 13(a-c) show a lintel according to another embodiment with spaced lugs along the upper flange where FIG. 13(a) is an end elevation view, FIG. 13(b) is a side elevation view, and FIG. 13(c) is a perspective view.

[0060] FIGS. 14(a-c) show the lintel of FIGS. 13(a-c) in an example use where FIG. 14(a) is an end elevation view, FIG. 14(b) is a perspective view, and FIG. 14(c) is a close up end elevation view of the top portion of the lintel with a metal strap.

DETAILED DESCRIPTION OF THE INVENTION

[0061] FIGS. 5 and 7 show a structural lintel 10 according to a first preferred embodiment of the present invention. The lintel 10 is similarly shaped as an I-beam having a horizontal lower (or bottom) flange 12, a horizontal upper (or top) flange 13 and a vertical web 14 extending therebetween. The flanges 12 and 13 are parallel with the web 14 extending therebetween. The flanges 12 and 13 and the web 14 form spaces 19a and 19b, at respective lateral sides of the web 14.

[0062] Unlike a typical I-beam where the upper and lower flanges are similar in width, the upper flange 13 is narrower in width than the lower flange 12. The edges of the upper flange 13 are disposed inwardly of the edges of the lower flange 12that is, the edges of the upper flange 13 do not extend past the respective edges of the lower flange 12 (as can be seen from the end view in FIG. 5).

[0063] Further, the upper flange 13 is offset to one side of the web 14 as viewed from the cross-section. The space 19a to one side of the web 14 thus has more of the upper flange 13 forming it than the space 19b to the other side of the web 14.

[0064] The upper and lower flanges 12 and 13 have a thickness of 10 mm and the web 14 also has a thickness of 10 mm, for reasons described below.

[0065] Referring to FIG. 6, the depth of the lintel 10 is determined by the height of the web 14. The height of the web 14 is chosen such that the internal depth, being the distance between the facing internal surfaces 12i and 13i of the lower flange 12 and the upper flange 13 is equal to:

Number of brick courses (N)*Depth of each brick in mm (D)+(N1)*Mortar Course Thickness in mm (M)

[0066] Where N2

[0067] N is the number of brick courses, with a minimum of 2 courses.

[0068] DDepth of each brick is typically 76 mm, but can vary

[0069] Mmortar course thickness is generally 10 mm.

[0070] The lowermost and uppermost brick courses abut against the internal surfaces 12i and 13i of the lower flange 12 and the upper flange 13 respectively, with mortar having a typical thickness of 10 mm therebetween. As the brick courses abut the flanges 12 and 13, there is one less (N1) number of mortar layers between the flanges 12 and 13. Thus, only the depth of the mortar course between two courses of bricks are part of the calculation.

[0071] A standard brick course is equivalent to the depth of a brick (commonly 76 mm) plus a mortar course thickness generally of 10 mm, which equals 86 mm/course. The top flange 13 of the lintel is considered a mortar course.

[0072] The internal distance between the top and bottom flange 13 and 12 of the lintel 10 is equivalent to the number of courses (greater than or equal to 2), less the flange equivalent to a mortar course (10 mm). The distance between internal surfaces 12i and 13i for 2 course, 3 course and 4 course lintels are 162 mm (86 mm2-10 mm), 248 mm (86 mm3-10 mm) and 334 mm (86 mm2-10 mm) respectively.

[0073] The overall depth of a lintel 10 is the distance between external faces of the lower and upper flanges. This is thus the distance between the internal surfaces noted above, plus the thicknesses (10 mm each) of the lower and upper flanges. For 2 course, 3 course and 4 course lintels, the overall depths are 182 mm, 268 mm and 354 mm respectively.

[0074] FIG. 6 shows an example of a 3 course depth lintel 10 with bricks 200 and mortar layers 210. The lintel 10 comprises a series of spaced holes 17 formed along the web 14 which are at a height corresponding to the mortar layers 210.

[0075] The space 19a is designated for the inside wall and the space 19b is for the outside wall. The top flange 13 has a width designed to allow a maximum brick overhang on the inside wall of 25 mm to comply with building regulations, as well as provide sufficient mortar cover to the edge of the flange 13 when the mortar joint between the brick under the flange and the brick above it, is ironed.

[0076] The part of the top flange 13 projecting partway onto the external brick skin 230 is designed to provide the maximum opportunity for the bricklayer to align the face brick to coursework by tilting the brick up or down with minimal interference from the top flange 13 on that side. The part way projecting flange also maximises the mortar bed width on the external side of the brick wall 230 for durability. The top flange thickness is the same as the mortar course, and is generally 10 mm.

[0077] The bottom flange 12 width is preferably 210 mm so that the brick course overhang of the plate each side is a maximum 10 mm and the holes through the brick are not visible along the side of the flange, however the more commonly available width is 200 mm. The bottom flange plate thickness is 10 mm.

[0078] Connecting the top flange 13 to the bottom flange 12 is a vertical and perpendicular web 14. The web 14 is centrally located on the bottom flange 12, which for a 210 mm wide flange gives a centreline distance of 105 mm from each edge of the flange. The web thickness is less than or equal to 10 mm, so when bricks are laid against each side the overall wall thickness of 230 mm can be obtained without cutting down the commonly available 110 wide brick. The web 14 is offset from the centre of the top flange 13 so that wall support, alignments and mortar cover to the flange sides is achieved.

[0079] Referring to FIG. 8, holes 17 are equi-spaced along the web and aligned centrally to the axis of the mortar course between brick courses. The holes are used for brick ties 31 access from front of the lintel to the back (from the space 19a to 19b), so the brick wall is tied together. Where required, shear connectors 32 are deployed in the holes 17 and into the mortar beds of the brickwork each side of the lintels so shear forces can be transferred from the beam 10 into the brickwork, increasing the overall strength of the lintel.

[0080] Referring to FIGS. 9 and 10, another aspect to the present invention is a lintel 10b with a centrally located orthogonal web 14 on a bottom flange 12. The lower flange 12 is as wide as a brick-wall width less a small amount for brick overhang (generally 20 mm maximum) on each side. The lintel 10b includes a centrally located top flange 13 of lesser width than the bottom flange 12. The width of the top flange 13 is sufficient to maximise the bricklaying access as well as the structural capacity of the beam as compared with prior art PFC and plate welded composite structural beams.

[0081] The lintel of the invention is sized to suit brick coursework, with flange thickness matching the mortar course thickness. The shape of the lintel enables brickwork to be installed both sides of the lintel to create a finished wall on each side. The top flange of the lintel is concealed within the brick mortar course.

[0082] The preferred embodiments of the invention provide an improved design for a structural garage lintel which: [0083] 1. Has a number of lintels whereby each lintel depth measured between the bottom flange and the top flange matches the corresponding depth of two or more brick courses minus a mortar course. [0084] 2. Have a flange thickness in its preferred embodiment common to all lintel sizes and less than or equal to the generally accepted mortar course thickness of 10 mm. [0085] 3. Have beam strengths increased or decreased by varying the depth of the beam in multiples of brick coursing minus a mortar course between the flanges of the lintel [0086] 4. Standardise the top flange width of each lintel so that there is sufficient strength capacity to the beam and sufficient mortar cover to conceal its edges. [0087] 5. Has holes equi-spaced along the web corresponding in height with the mortar course of the brickwork, which can allow brick ties to be installed between the external and internal skin of brickwork. [0088] 6. Has holes equi-spaced in the web corresponding to the brick mortar coursing which can also be used to install a steel shear connector, which can be employed to improve the composite strength of the beam due to brickwork. [0089] 7. Doesn't need individual web stiffeners welded within the beam at locations where it supports other intersecting beam loads, and at the lintels support each side of the opening, due to direct loading and transfer of the loading into the brickwork sandwiched between the top and bottom flanges of the lintel.

[0090] The present invention aims to overcome the disadvantages of garage lintel technology by providing a structural lintel which combines all the construction advantages of a T bar lintel combined with the structural capacity of a steel beam.

[0091] The web thickness in the lintel beams in the examples are 10 mm, but this can be varied and can be thinner. The preferred maximum width is 10 mm, which is the perp mortar joint thickness between 2 off bricks laid side by side, giving a 230 mm wide wall. This wall is made from 2110 mm wide bricks plus the central perp mortar joint between them (now replaced by the web of the beam). The web can be a little thicker and can be smaller if structurally adequate. Other example web thickness include 6.23 mm and 8 mm etc, the thickness governed by strength considerations and economy.

[0092] As mentioned above, the industry employs structural angles 140 as lintels as shown in FIG. 11(a).

[0093] FIGS. 11(b) to FIG. 12 show structural angle lintel/brick assemblies and variations thereof that will be able to replace current industry lintels.

[0094] The lintel 10c comprises a C-section beam having a horizontal bottom flange 12, a horizontal top flange 13 and a vertical web 14 extending between aligned side edges of the bottom flange 12 and the top flange 13. The top flange 13 is narrower than the bottom flange 12. The bottom flange width is generally 100 mm wide. The depth of the lintel 10c (height of the web 14) depends on the number of courses to be received as described below. The typical thickness of the lintel 10c is 5 mm.

[0095] The common dimensions of structural angles 140 used in the industry (bottom flange width in mmweb height in mmflange/web thickness in mm) are 1001006 mm, 10010010 mm, 1501006 mm and 1501006 mm all in hot dipped galvanised, and supplied in a number of standard lengths to suit window and door openings. They are generally deployed in brick veneer construction, supporting the external brickwork over the openings.

[0096] Lintel 10c-1 is a one brick course depth lintel, which will replace the conventional 1001006 mm angle lintel 140. Lintel 10c-2 is a two brick course depth lintel and lintel 10c-3 is a three brick course depth lintel. There is a thin mortar bed 210 on top of the bottom flange 12 of 5 mm below the lowermost brick course, and the top of the uppermost brick course will 200 will abut the underside of the top flange 13. Mortar layers 210 are disposed between the brick courses. The brick course 200b on top of the uppermost brick course will have a 10 mm mortar course on the brick below, and a 5 mm thin bed mortar on top of the lintel top flange 13.

[0097] The lintel is laid on top of the bricks either side of the window or doorway. The bricks laid within the lintel will have the 10 mm mortar course between the bricks (for two or more courses) as per the rest of the wall. However, when laid on top of the bottom flange, the mortar is only 5 mm thick.

[0098] The overall height depth of the lintel (between external surfaces of the top and bottom flange) for a single brick lintel will be 91 mm (5 mm bottom flange+5 mm thin mortar bed on top of bottom flange+76 mm brick depth+5 mm top flange).

[0099] The overall height/depth of the lintel (between external surfaces of the top and bottom flange) for a two course lintel will be 177 mm (5 mm bottom flange+5 mm thin mortar bed on top of bottom flange+76 mm brick depth+10 mm mortar course+76 mm brick depth+5 mm top flange).

[0100] The overall height/depth of the lintel (between external surfaces of the top and bottom flange) for a three course lintel will be 263 mm (177 mm above for two course lintel above+76 mm brick depth+10 mm mortar course).

[0101] Considering the bottom flange thickness+5 mm thin mortar bed on top of bottom flange comprises a 10 mm mortar course equivalent, the overall height of the lintels will be Nbrick courses (one course=10 mm mortar+76 mm brick height plus=86 mm) plus 5 mm top flange thickness. So, a single brick course C-lintel will be 91 mm, 2 courses is 177 mm, 3 courses is 263 mm.

[0102] The top flange 13 further includes spaced holes 18 which will allow mortar filling and contribute positively to increased bonding between the lintel and the brick wall. The web 14 also includes holes 17 aligned centrally to the axis of the mortar course between brick courses, for the two or more brick course embodiments.

[0103] FIG. 12 shows lintels 10d-1 and 10d-2 which are similar to the lintels 10c-2 and 10c-3 respectively. The lintels 10d however have the top flange 13 extending past the other side of the web 14 and thus into the wall cavity in use. Because the minimum brick cavity is 25 mm, that is the maximum overhang of the top flange 13 for this design arrangement.

[0104] The C-section lintel 10c is the preferred design as it could be roll formed, whereas the lintel 10d would need to be a welded beam.

[0105] All these lintels will produce composite action, or increased capacity because of the laid brick interacting with the steel lintel.

[0106] FIG. 13 shows a structural lintel 10f according to another embodiment of the present invention. The lintel 10f is similarly shaped as the lintel 10b of FIGS. 9 and 10. The lintel 10f comprises an I-beam having a horizontal lower (or bottom) flange 12, a horizontal upper (or top) flange 13 and a vertical web 14 extending therebetween. The top flange 13 is centrally located of lesser width than the bottom flange 12.

[0107] The lintel 10f includes a plurality of lugs 29 mounted in a spaced manner along the top surface 33 of the upper flange 13. The lugs 29 generally comprise upside down U-shaped rods or beams with ends thereof mounted by welding to the top surface 33. The lugs 29 thus form tie-down formations with openings along the top surface 33. The lugs 29 are aligned with the web 14.

[0108] FIG. 14 shows an example use which is similar to that shown in FIG. 6, being a 3 course depth bricks 200. Metal strapping 35 is passed through the opening of the lugs 29 by the brick layer, and the strapping 35 is pulled up between the bricks 220 as they are being laid along the top surface 33, The upper ends of the strapping 35 are either turned over on top of a timber plate 37 and attached thereto or tied directly to a rafter of roof truss.

[0109] In prior art assemblies, there is nowhere to attach roof hold down straps except for folding the strap underneath a few brick courses immediately below the point of fixing, which is only a portion of the restraint required in some cases.

[0110] The lugs 29 with the strapping 35 effectively ties the roof structure to all the bricks as well as the beam lintel, across the garage opening for example, which solves a lot of hold down issues, especially for sheet roofs. The hold down means not only includes the brick dead weight but also the mass of the steel beam lintel.

[0111] The strap can be simply fed through the lugs by the bricklayer which is another advantage.

[0112] The strap upper ends can be fanned out along the timber plate so that each end of the strap can be spaced apart to reduce the span of the timber plate (between the hold down points) which means the timber plate size and strength can be maximised to hold down a roof structure that is fixed to it.