Lintel Support, Masonry Support Kit, and Lintel Support Method

Abstract

The present invention includes a lintel support to aid in lintel repair and/or reinforcement. The lintel support has a body with a top, a bottom, and a height extending therebetween; at least one claw at the top; and a bracket at the bottom. In use, points are dug out of a mortar line above the lintel and the claws of the lintel support are positioned into those points. With the claws so positioned, the bracket will be below the failing lintel. A support beam is placed under the bracket and a jack lift provides uplift at the mortar line where the claws are positioned.

Claims

1. A lintel support comprising: a flat body with a top, a bottom, a height extending between said top and said bottom, and a claw side and a non-claw side; at least one claw extending perpendicularly from said top of said claw side of said body; and a bracket extending perpendicularly from said bottom of said claw side of said body.

2. The lintel support as claimed in claim 1, wherein said at least one claw comprises: a center claw disposed directly over said bracket; a right claw to the right of said center claw; and a left claw to the left of said center claw.

3. (canceled)

4. The lintel support as claimed in claim 1, wherein said height of said body is between 15 and 20 inches.

5. The lintel support as claimed in claim 1, wherein said bracket comprises bracket right and left sides and bracket supports extending between said bracket right and left sides and said body.

6. The lintel support as claimed in claim 1, further comprising at least one claw reinforcement extending substantially between said bottom of said body and said at least one claw, and wherein each of said at least one claw reinforcements is a brace extending perpendicularly out from said body.

7. (canceled)

8. The lintel support as claimed in claim 2, further comprising: a center claw reinforcement extending substantially between said bottom of said body and said center claw; a right claw reinforcement extending between said center claw reinforcement and said right claw; and a left claw reinforcement extending between said center claw reinforcement and said left claw; wherein each of said center, right, and left claw reinforcements is a brace extending perpendicularly out from said non-claw side of said body.

9. The lintel support as claimed in claim 2, wherein: said bottom of said body comprises a bracket width; said top of said body comprises a claw width extending across said right, center, and left claws; said bracket width is less than said claw width; and said body further comprises a right angled side extending between said bracket and said right claw and a left angled side extending between said bracket and said left claw.

10. The lintel support as claimed in claim 1, wherein said at least one claw is at least two claws and said lintel support further comprises a space between said at least two claws.

11. A masonry support kit comprising: at least two lintel supports, wherein each of said at least two lintel supports comprises: a flat body with a top, a bottom, a height extending between said top and said bottom, and a claw side and a non-claw side, wherein said bottom comprises a bracket width; at least one claw extending perpendicularly from said top of said claw side of said body; and a bracket extending perpendicularly from said bottom of said claw side of said body, wherein said bracket comprises a bracket hole.

12. The masonry support kit as claimed in claim 11, further comprising: a spreader comprising: a spreader length; a spreader depth; a plurality of spreader holes disposed along said spreader length, wherein a diameter of said spreader holes is less than said bracket width of each of said at least two lintel supports; and means for holding said bracket holes of said at least two lintel supports in place relative to at least two of said plurality of spreader holes of said spreader.

13. The masonry support kit as claimed in claim 11, further comprising a support beam.

14. The masonry support kit as claimed in claim 11, further comprising a jack lift.

15. A method for supporting masonry using at least one lintel support, wherein the at least one lintel support comprises a body with a top, a bottom, a height extending between the top and the bottom, and a claw side and a non-claw side; at least one claw extending perpendicularly from the top of the claw side of the body; and a bracket extending perpendicularly from the bottom of the claw side of the body, wherein said method comprises the steps of: selecting at least one point in a first mortar line above a failing lintel; removing mortar from the at least one point in the first mortar line; setting the at least one claw of the at least one lintel support into the at least one point with removed mortar such that the bracket of the at least one lintel support is disposed below the failing lintel; disposing a support beam beneath the bracket of the lintel support; disposing a jack lift beneath the support beam; and applying upward pressure from the jack lift.

16. The method as claimed in claim 15, further comprising the step of adding at least one shim above the failing lintel.

17. The method as claimed in claim 16, wherein said step of adding at least one shim above the failing lintel comprises the steps of: removing mortar from a third mortar line; and introducing the at least one shim into the space created by the mortar removal from the third mortar line; wherein the third mortar line is above the failing lintel and below the first mortar line.

18. The method as claimed in claim 17, further comprising the step of injecting caulk in front of the at least one shim.

19. The method as claimed in claim 16, wherein said step of adding at least one shim above the lintel comprises adding the at least one shim directly above the failing lintel.

20. The method as claimed in claim 16, further comprising the steps of: removing mortar from at least one second mortar line above the first mortar line on either side of the at least one lintel support; injecting masonry repair grout into a space created by the removed mortar from the at least one second mortar line; and inserting at least one helical embedment bar into the masonry repair grout.

21. The method as claimed in claim 15, further comprising the steps of: removing mortar from at least one second mortar line above the first mortar line on either side of the lintel support; injecting masonry repair grout into a space created by the removed mortar from the at least one second mortar line; and inserting at least one helical embedment bar into the masonry repair grout.

22. The method as claimed in claim 21, wherein said step of inserting at least one helical embedment bar into the masonry repair grout comprises: inserting a first helical embedment bar into the masonry repair grout; injecting additional masonry repair grout; and inserting a second helical embedment bar into the masonry grout.

23. The method as claimed in claim 21, further comprising the step of injecting caulk in front of the at least one helical embedment bar.

24. The method as claimed in claim 15, wherein: said step of setting the at least one claw of at least one lintel support comprises setting the at least one claw of at least two lintel supports; and said method further comprises the steps of: attaching the brackets of the at least two lintel supports to a spreader; and disposing the spreader between the at least two lintel supports and the support beam.

25. The method as claimed in claim 15, further comprising the steps of: removing the failing lintel; and replacing the failing lintel with an undamaged lintel.

26. A lintel support comprising: a flat body with a top, a bottom, a height extending between said top and said bottom, and a claw side and a non-claw side; at least one claw extending perpendicularly from said top of said claw side of said body, wherein said at least one claw comprises: a center claw; a right claw to the right of said center claw; and a left claw to the left of said center claw; and a bracket extending perpendicularly from said bottom of said body.

27. The lintel support as claimed in claim 26, further comprising: a center claw reinforcement extending substantially between said bottom of said body and said center claw; a right claw reinforcement extending between said center claw reinforcement and said right claw; and a left claw reinforcement extending between said center claw reinforcement and said left claw; wherein each of said center, right, and left claw reinforcements is a brace extending perpendicularly out from said non-claw side of said body.

28. The lintel support as claimed in claim 26, wherein: said bottom of said body comprises a bracket width; said top of said body comprises a claw width extending across said right, center, and left claws; said bracket width is less than said claw width; and said body further comprises a right angled side extending between said bracket and said right claw and a left angled side extending between said bracket and said left claw.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1a is a front view of a preferred lintel support of the present invention showing the non-claw side of the lintel support body.

[0032] FIG. 1b is a right side view of the lintel support shown in FIG. 1a.

[0033] FIG. 1c is a perspective view of the non-claw side of the lintel support shown in FIG. 1a.

[0034] FIG. 1d is a perspective view of the claw side of the lintel support shown in FIG. 1a.

[0035] FIG. 2 is a perspective view of two lintel supports of the present invention in use with a spreader.

[0036] FIG. 3 is an illustration of two lintel supports of the present invention in use with a brick wall over a damaged lintel.

[0037] FIGS. 4a and 4b include a flow chart of the steps of the preferred method of the present invention.

DETAILED DESCRIPTION

[0038] Referring first to FIGS. 1a-1d, various views of lintel support 10 are provided. Lintel support 10 includes body 22 with top 50 and bottom 52 and height 24 extending therebetween. Body 22 has smooth claw side 84, shown most clearly in FIG. 1d, and non-claw side 86 that may not be smooth due to the inclusion of claw reinforcements 26, as discussed below. Bottom 52 includes bracket 20, shown most clearly in FIG. 1d. Bracket 20 is a tab of material extending perpendicularly out from bottom 52 of body 22. Top 50 includes at least one claw 12. The preferred embodiment with three claws 12, center claw 14, right claw 16, and left claw 18, is shown.

[0039] There are spaces 68 between left claw 18 and center claw 14 and between center claw 14 and right claw 16. Bottom 52 has bracket width 64, which is also the width of bracket 20. Top 50 has top width 66, which is the width across all claws 12. With right angled side 70, left angled side 62, and the fact that top width 66 is greater than bracket width 64, body 22 has a roughly triangular shape. Claws 14, 16, 18, as best shown in FIGS. 1c and 1d, are also tabs extending perpendicularly out from body 22. As is shown and preferred, claws 14, 16, 18 and bracket 20 each extend out perpendicularly from body 22 from claw side 84 of body 22. It is understood, however, that bracket 20 and claws 14, 16, 18 may extend out perpendicularly on both claw side 84 and non-claw side 86 of body 22 or that bracket 20 and claws 14, 16, 18 may extend out perpendicularly in opposite directions from body 22.

[0040] Bracket 20 includes bracket supports 30, which extend from bracket right and left sides 80, 82 to attach to body 22. Claws 12 also have claw reinforcements 26. Center claw reinforcement 56 extends substantially between center claw 14 and bottom 52 of body 22. Right and left claw reinforcements 58, 60 extend between center claw reinforcement 56 and right and left claws 16, 18, respectively. Claw reinforcements 26 are disposed on non-claw side 86 of body 22. Claw reinforcements 26, including center, right, and left claw reinforcements 56, 58, 60 are preferably sturdy, rigid braces that extend out perpendicularly from body 22 and protect against deflection of body 22 when lintel support 10 is in use. Body 22 also includes body holes 32 that are handholds and may be omitted. Bracket 20 includes bracket hole 36, which may be used in conjunction with a spreader 38, as discussed below with reference to FIG. 2.

[0041] Now referring to FIG. 2, a perspective view of two lintel supports 10 positioned with spreader 38 is provided. Masonry support kit 90 includes at least one lintel support 10 and may also include spreader 38, especially when more than one lintel support 10 is included in kit 90, as shown in FIG. 2. Spreader 38 has spreader length 40, spreader depth 72, and several spreader holes 42 along spreader length 40. This kit 90 also includes means for holding the lintel supports' bracket holes 36 in place relative to spreader holes 42. These means are not visible in this view, but it is understood that the bracket holes 36 are aligned with the spreader holes 42 and means, such as a screw or peg, are utilized to maintain this alignment and position. Spreader 38 must include spreader depth 72 so that these means have room to extend through both the bracket holes 36 of the lintel supports 10 and the spreader holes 42 of the spreader 38.

[0042] Now referring to FIG. 3, an illustration of a kit 90 of the present invention in use with a brick wall 76 and a failing lintel 78 is provided. Kit 90 may include support beam 72 and a jack lift (not shown). It is understood that a spreader 38 could be used in such an illustration and would be disposed between the lintel supports 10 and the support beam 72 if it were included, or alternatively that spreader 38 may be support beam 72. Claw reinforcements 26 face away from claws 12 and support body 22 from buckling when pressure is applied, as described below. First, second, and third mortar lines 87, 88, 89 are indicated, respectively, and discussed below with reference to method 100.

[0043] The mason has selected points in the first mortar line 87, which is three bricks up the brick wall 76; removed the old grout at those points; positioned claws 12 of lintel supports 10 in the spaces made with the removal of the grout at the points; positioned support beam 72 beneath brackets 20 of lintel supports 10 and provided uplift from the jack lift below the support beam 72. This removes substantial pressure from failing lintel 78. With that pressure relief, the mason may introduce shims and/or helical embedment bars, as discussed below with reference to method 100 of the present invention. In some circumstances, the mason may even completely remove the old failing lintel 78 and replace it. No prior art, other than complete deconstruction and reconstruction offers this option.

[0044] Now referring to FIG. 4a, a flow chart illustrating the steps of method 100 of the present invention is provided. Across the top are the steps of method 100 in its most basic form: selecting at least one point in a first mortar line above a failing lintel 102; removing mortar from the point(s) in the first mortar line 104; setting the claw(s) of the lintel support(s) into the point(s) with removed mortar so that the bracket(s) of the lintel support(s) are disposed below the failing lintel 106; disposing a support beam beneath the bracket of the lintel support 108; disposing a jack lift beneath the support beam 110; and applying upward pressure from the jack lift 112. The steps of attaching the brackets of at least two lintel supports to a spreader 126 and disposing the spreader between the lintel supports and the support beam 128 may be included between steps 106 and 108.

[0045] Now referring to FIG. 4b, additional optional steps of method 100 beyond its most basic form are provided. Method 100 may also include the step of adding at least one shim above the failing lintel 114, which includes the steps of removing mortar from a third mortar line 116; and introducing the shim(s) into the space created by the mortar removal from the third mortar line 118, where the third mortar line is above the failing lintel and below the first mortar line. It is preferred that the following additional step be performed after step 118 for the sake of aesthetics: injecting caulk in front of the shim 140.

[0046] Method 100 may also include the steps of removing mortar from at least one second mortar line above the failing lintel on either side of the at least one lintel support 120; injecting masonry repair grout into a space created by the removed mortar from the at least one second mortar line 122; and inserting at least one helical embedment bar into the masonry repair grout 124. It is preferred that the following additional step be performed after step 124 for the sake of aesthetics: injecting caulk over the at least one helical embedment bar 142. As it is preferred that two helical embedment bars are used, the steps may be: removing mortar from at least one second mortar line above the failing lintel on either side of the at least one lintel support 120; injecting masonry repair grout into a space created by the removed mortar from the at least one second mortar line 122; inserting a first helical embedment bar into the masonry repair grout 124; injecting additional masonry repair grout into the space in front of the first helical embedment bar 136; and inserting a second helical embedment bar 138. In some embodiments, more than one second mortar line may be selected for reinforcement with helical embedment bars. Field operations have shown that this may be preferred in situations that include a large number of failure points. As such, steps 120, 122, and 124 (and 136 and 138) may be repeated at a second second mortar line.

[0047] Method 100 may also include the steps of removing the failing lintel 130 and replacing the failing lintel with an undamaged lintel 132. Steps 126, 128; 114, 116, 118; 120, 122, 124; and 130, 132 are not mutually exclusive sets of steps but may all be performed or performed in combinations, in addition to the basic steps that method 100 always includes— 102, 104, 106, 108, 110, and 112. While steps 130 and 132 cannot be performed without steps 102, 104, 106, 108, 110, and 112 having been performed, steps 114, 116, and 118 may occur before, during, or after these steps, but preferably after. Similarly, steps 120, 122, and 124 may occur before, during or after these steps, but preferably after.

[0048] Referring again to FIG. 3, exemplary first, second, and third mortar lines 87, 88, 89 are indicated. In step 102, points are selected from first mortar line 87 to correspond with where claws 12 will be set in step 106. Third mortar line 89 is directly above failing lintel 78 and this is where shims may be added in step 114. Second mortar line 88 is preferably two feet above first mortar line 87.

[0049] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein.