Let’s Rethink Lintels

Written by {ga=tom-ward}
Wednesday, November 09 2011 13:57 - Last Updated Friday, March 09 2012 17:18

Built-in-place masonry offers most efficient installation as well as

a design element

For as long as I have been in the trade (17 years), it seemed that the only options considered
for crossing an opening were steel or heavy, less than aesthetically pleasing, precast lintels. As
masons, whenever we work on or view older masonry buildings, we stand back in awe. The
volume of masonry and the workmanship itself is humbling. These buildings, their designs and
details have stood the test of time. If we take a closer look at them, we notice some elements
missing, such as steel lintels. Many of the buildings have stone or brick arches over windows
and doors, with virtually all openings constructed in this manner. At one time, masons must
have been proficient with this technique. I think it’s safe to say we will never build them like they
used to, but that doesn’t mean we can’t still learn from them and help reinvent our product and
ourselves as craftsmen. After all, what will the masons 100 years from now say when working
on that new addition to one of our buildings?

Field perspective: built-in-place masonry lintels

Options for lintels are typically cast-in-place masonry, steel or precast. Of the three, the
cast-in-place masonry lintel offers the most in added value for our buildings and, more
importantly, for our customers. Yet, it is often the last option considered. Steel lintels are usually
sent out on one load, then we get to unload, handle, re-handle, sort and manage the stock pile
until it is finally used. This adds wasted time and effort to every project. Wasted time equals
wasted money. Something our customers and contractors certainly would rather not pay for. Not
to mention the cost of the steel itself! Over time steel lintels, at the very least, will need to be

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Let’s Rethink Lintels

Written by {ga=tom-ward}
Wednesday, November 09 2011 13:57 - Last Updated Friday, March 09 2012 17:18

repainted. They can also rust, corrode and expand, pushing the surrounding brick out of place.
Precast lintels have disadvantages also. If you have never installed or lifted one, they are very
heavy and awkward to handle and install. Possible risk of back strain is always a concern for a
mason. Like steel lintels, they have to be ordered and handled multiple times before they are
installed. Bond doesn’t always work with the scores and they tend to chip while handling or
come with chips larger than we would accept in a concrete masonry unit laid in the wall. If a
block has a chip that is unacceptable, it can be saved for above the ceiling or for cutting to a
smaller size. Even if a chipped block is discarded, waste cost remains low. Precast lintels are
expensive, therefore typically installed as is. As a result, precast lintels do not always have a
seamless finish and may be unsightly to the owner.

Cast-in-place masonry lintels offer many benefits for openings in CMU walls. Recently
Davenport Masonry completed a large addition to a Detroit area hospital. The spec gave the
option of precast or built-in-place lintels. Even though none of the CMU was exposed, we
decided on built-in-place for several reasons.

- The course above the windows was a continuous lintel.

- Continuity of the rebar would have been interrupted at every precast lintel.
- Window openings were 7´ and spaced every 6´.
- Choosing cast-in-place lintels minimized the number of lap splices, saving rebar and
simplified rebar orders. Only two lengths of rebar were needed between control joints. With the
spacing of the control joints consistent throughout the project, the entire crew knew exactly
which to use and where, two 20s and two 12´ #5 reinforcing bars were used for continuous lintel
spacing 30´ over multiple openings. Pre-planning and ordering the rebar pre-cut as much as
possible is a real time saver but only if you share the information with your entire crew. A load of
preplanned rebar simply becomes an out of control pile if the crew doesn’t know where and
when to use the different lengths.
- Precast lintels would have been 8´8˝. Why have the crews struggle with these heavy units
when a safer, easier method exists?
- Crews gained knowledge and experience constructing masonry lintels and also played a
big part in refining the system.

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Let’s Rethink Lintels

Written by {ga=tom-ward}
Wednesday, November 09 2011 13:57 - Last Updated Friday, March 09 2012 17:18

Problems or opportunities?

Now, exactly how do we build cast-in-place lintels effectively, consistently and with the same
continuity as running the wall up? This may seem like a problem but it really is an opportunity to
improve our skill level, improve the buildings we construct and improve the bottom line for all
involved. Let’s start by looking at what the bricklayer does once the frame/form work is up and
installed on a CMU reinforced wall. He simply lays block over the form just as if running the rest
of the wall, but this means a plan is needed on how to prep the opening before the mason
reaches lintel height. Once the system is established and the prep work is done, you will be
surprised at how easy and productive cast-in-place lintels can be.

Typical window or door heads are about 7´4˝. With reinforced CMU walls and grout lifts every
4´, the lintel course is a natural point to grout all cells with vertical rebar, as well as the lintel.
First, the bricklayer pours about one inch of grout in the lintel block (solid bottom bond beam),
adds the rebar, then tops off the bond beam with grout and consolidates the grout with his
trowel or a puddle stick. Rebar placement is critical to prevent cracking. Even masons who are
trained in grouting benefit from a wall briefing to establish what is expected and required. Crews
want to perform and they do it best when they know exactly what to do, including all the details.
They need to understand how and why rebar position is critical to a successful cast-in-place
masonry lintel.

Brainstorm ideas, plan, then execute

Good leadership encourages ideas from all involved in the project. At the above mentioned
project, after we decided on cast-in-place lintels, it was decided to challenge the conventional
method of forming for these lintels. I wanted to simplify the whole process and didn’t want to use
any power tools, nails or center kickers or even a hammer to install the form work. The basic
idea was a simple clamp-and-go system that would have bearing ledges for the reusable

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Let’s Rethink Lintels

Written by {ga=tom-ward}
Wednesday, November 09 2011 13:57 - Last Updated Friday, March 09 2012 17:18

header form. Starting with large c-clamps modified with a 3˝ x 3˝ angle welded for support, the
concept seemed good. After brainstorming with some of the crew who showed interest in the
idea, we built a prototype, tested it with four times the intended load, then made enough to build
eight lintels. Before production crews began, the prep team simply clamped modified c-clamps
to the jambs, placed a pre-made wood header with tabs to prevent the header from falling out.
Now the wall is ready for the production crew. With every opening fully prepped, the masons
had no down time waiting on form work. Steel angle iron placed in the bed joint can be used in
certain situations. Just remember, larger openings will require longer legs of the angle. They
can be difficult to remove if you only have access from one side and if the angle extends past
the shell face into the grouted cell, it may leave a weak point in the pour.

Details and time savers

With possibilities and variations of masonry lintels seemingly endless in regard to location, type
and size, covering every one would be impossible. From the complex multi-course cast-in-place
lintel with stirrups to the simple single course over the typical 40˝ door, the approach is the
same. Understand the design. Review and discuss details with the crews that will be building
them. Brainstorm ideas to address any constructability issues. Bricklayers don’t have to be

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Let’s Rethink Lintels

Written by {ga=tom-ward}
Wednesday, November 09 2011 13:57 - Last Updated Friday, March 09 2012 17:18

experts in design, just professional in execution. Remember, if an issue prevents the lintel from
being constructed as shown, we owe it to our customers to solve the problem. We have great
resources and training available to solve these exact issues. Architects, International Masonry
Institute (IMI) and Masonry Institute of Michigan (MIM) are more than willing to help solve
almost any issue before it becomes a problem for us and our customers.

Pictured are time saving details that will help produce a seamless and natural looking masonry
lintel and proper placement of the rebar. With multi-course lintels, I prefer to lay, then grout each
course one at a time, as long there is no cold joint formed between successive courses. This
will ensure proper coverage, placement of the rebar and minimize mortar droppings.

Each project will have different challenges. Lintels are just one area where we can make
improvements in the building’s quality, bricklayers skill level and production and increase value
and appeal to the clients investment. By specifying cast-in-place masonry lintels or offering
mason contractors a choice, designers can help turn around and witness the rebirth of this
noble craft on a new generation of buildings.

Photos by Mark DeMarco

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