Keystone Lintels Ltd

The self-build project is situated in the small coastal village of Borth and stands prominent on the cliff overlooking three miles of gently shelving golden sand. The private dwelling offers a breath-taking vantage point for the homeowners achieved by Keystones carefully considered bespoke bow lintel design for a 13.7m curved span panoramic living room window on the upper floor.ChallengeKeystone’s technical team appreciates the importance of personalisation and were tasked with turning the clients dream vision for the family home into a reality. The unique structure would require a continuous irregular lintel to accommodate the variations of internal and external curves above each opening for the perimeter of the living room.The lintel was designed to incorporate the distinct feature window which will add interest to the room and soften the space where light would enter.SolutionKeystone’s technical engineer was tasked with creating a structural steel solution capable of accommodating the curved structure and unusual loading conditions – tailor made to suit the lifestyle requirements of the client.The engineer worked closely with the client to develop the lintel for the complex curved opening and provided comprehensive technical support from design through to installation. This included a site visit to ensure all measurements were accurate with minimal tolerance. For buildability and logistical purposes, the 13.7m bespoke bow lintel was delivered as five separate components and fixed together on site.The innovative and intelligent design fitted and aligned perfectly with the contours of the building and achieved the desired continual curved opening bringing a sense of flow and energy to the room. Keystone lintels also provide special lintels in stainless steel to prevent corrosion in buildings that are subjected to aggressive environmental conditions, typically in coastal locations within 500m of the shoreline.Testimonial“I was unsure if the vision I had for this project was even possible, but Keystone’s team of engineers offered a creative and effective solution, ensuring an incredibly personalised touch to the building.”Lee JenkinsSelf-builder

Close to the historic market town of Nantwich, renowned for its medieval timbered architecture, Chamberlain Developments in association with DEP Architects have created nine bespoke two, three and four-bedroom homes in the wonderful bucolic village setting of Acton. Eighty intricate Keystone brick slip feature lintels feature across the ground and first floor door and window openings on the phase two development.ChallengeThe new homes are sympathetically placed around the restored and converted traditional 18th century farmhouse, ancillary barns and outbuildings from the initial phase one development, situated near the 13th century St. Mary’s Church. The architecture plans specified a combination of bespoke brick slip flat gauge arches, parabolic arches and bullseye lintels, each requiring a flawless brick surround finish in keeping with the heritage sensitivity of the site.The plans received from T G Builders Merchant originally included brick slip lintels for the front and rear elevations only, however, Keystone’s team were able to offer Chamberlain Developments a solution for the other more intricate brick details and the specification was therefore increased to include additional brick slip flat gauge arches and bullseye lintels for the side elevations.SolutionKeystones dedicated technical team ensured each bespoke lintel was manufactured to size, shape and aesthetic requirements within the project build schedule. A consignment of bricks were collected from site, cut and bonded offsite onto load bearing lintels using a BBA approved construction adhesive. The weatherproof controlled environment helped to guarantee a high quality brick finish and eliminated delays onsite from disruptive weather conditions.The flat gauge arches were designed with a 70-degree brick skew and all lintels were suited to a wall construction of 325mm, 215mm brick height and 102.5mm soffit return, removing the need for skilled labour onsite. The prefabricated brick slip lintels were delivered to site ready for final pointing, with larger and heavier lintels including lifting hooks for an easier and safer installation.Testimonial“We have specified Keystone many times before and have always been impressed with both the company’s products and customer support. At our Church Farm development, the brick slip feature lintels played a key part in the design of the new build homes. They look fantastic and the excellent detailing ensures they blend seamlessly with the rest of the brickwork.”Richard BullockContracts Manager at Chamberlain Developments

Halamar acquired this site in Beaconsfield. Planning permission was granted for a new build two-storey detached dwelling, replacing the existing residential property constructed in the 1900s.A comprehensive set of architecture plans specified high quality elevations with a ‘classical’ Georgian-esque design. The sub-contractors, B-Bespoke Design & Build Ltd, required Keystone’s brick slip flat gauge headers above multi-pane sash windows and an intelligent bespoke interconnecting brick slip splayed bay system across two floors on the side elevation.ChallengeThe design and scale of the building, along with the arrangement of fenestration and opening detailing, required the careful skill and use of sympathetic materials to ensure the development enhanced the special character of properties in close vicinity.B-Bespoke Design & Build Ltd considered the volume of decorative window openings and availability of local skilled bricklayers when considering the most effective and efficient approach to the build schedule.SolutionAn offsite construction method was deployed by the sub-contractor. Keystone’s technical team were contacted to design brick slip flat gauge headers accommodating brick spans between 1135mm to 1472mm. Each with a 70-degree end skew, 375mm high face brick and 102mm soffit return whilst also incorporating keystone stone headers above specific windows. The prefabricated lintels improved the allocation of time and resources elsewhere on site allowing the build to be completed to a high interior specification still with an exterior full of character.The rigid symmetrical design and gracious classic proportions create a generous sense of space and natural light, with stunning traditional period features created above each window opening. The interconnecting brick slip splayed bay system spans 1695mm and provides a stark contrast to the boxy room profiles often seen with a Georgian home. This architectural feature accommodates the high ceilings and desired aesthetics whilst providing effective structural support to withstand roof and masonry loads above.A consignment of bricks was collected from site and each brick cut and bonded using a BBA approved construction adhesive to the load bearing lintels offsite. The patented perforated lintel design allows the adhesive to squeeze through the perforations and form a ‘mushroom’ on the inside, providing a mechanical lock between the steel lintel and the brick slips.Testimonial“For the new build Georgian styled home, we sourced over thirty bespoke prefabricated brick slip feature lintels from Keystone as well as a unique interconnecting feature brick splayed bay system. As a smaller building contractor, we saved time and money using Keystone Lintels. We did not need to source additional skilled labour on site to create and replicate the intricate brick detailing which included Keystone stone headers. Ultimately this resulted in a faster build schedule for the client.”Nirmal DhaliwalSite Manager at B-Bespoke Design & Build Ltd

The former Marlow Railway Station dates back to 1873 and stood at the junctions of Station Road and Lock Road. The Old Coal Yard, adjacent to a station platform now only present, has been developed and designed by Bellwood Homes on the concept of three converted Victorian railway terraced buildings.Broadsman House, Palatine Place and Fenman Court consist of three 2-bedroom houses, eight 2-bedroom apartments and one 1-bedroom apartment providing commuters stylish suburban living. Keystones brick slip feature arch lintels and special segmental arch lintels encompass the traditional and contemporary balance of the housebuilders architectural vision.ChallengeThe fashionable commuter town on the Thames has been well preserved, limiting modern styled developments to maintain its original character and historic fabric of heritage buildings. Bellwood homes wanted a sense of purpose for their regeneration project – reconnecting people with what really matters to them, property location and design. The vernacular architecture provides both. A prime location for commuters to ride the branch line into London, renown as the ‘Marlow Donkey’, and fits subtly within the notable context of Georgian, Edwardian and Victorian styles of architecture in Marlow.SolutionKeystone’s technical engineer designed extra heavy-duty brick slip feature arch lintels for ground, first and second floor openings with a 1085mm span and 543mm rise. Over forty brick slip arches were manufactured by Keystone’s production team to a high quality and consistent finish. Each Hoskins Maltings Antique brick was cut to size and bonded using a BBA approved construction adhesive to the load bearing lintels. The patented perforated lintel design allowed the adhesive to squeeze through the perforations and form a ‘mushroom’ on the inside, providing a mechanical lock between the steel lintel and the brick slips.The offsite economical solution did not require skilled bricklayers on site to replicate each traditional arch. This saved approximately labour costs of one bricklayer per arch per day and ultimately weeks of the project build schedule. All prefabricated lintels were delivered to site and ready for final pointing in line with the phased construction plan of the three buildings being erected. The arches produced in a factory control environment were unaffected by torrential weather and winter reduced day light hours limiting productivity. This can often occur on other build schedules which lead to further delays in creating architectural features with real significance to the landscape.The offsite construction method facilitated onsite construction further by supporting bricklayers to recreate window tax designs, bricked up window spaces seen in buildings from the Victorian period. The detail of the façade is prominent most through the repetition of window arches positioned symmetrically on elevations facing the Marlow station. Keystones heavy-duty special segmental arches measuring a 2400mm span, with either a 600mm or 450mm rise provide a modern contemporary twist which feature above glazed bedroom windows and are in complete contrast to the smaller traditional arched windows striking a balance between old and new architecture.Testimonial“From R&D to installation we found Keystones prefabricated lintels very efficient. They reduce brick wastage approximately by 5%. Typically, traditional built arches would require one bricklayer for approximately six hours work. Therefore, this reduced labour costs on site whilst supporting bricklayers to achieve the desired architectural design.”Matthew McGillSite Manager at Bellwood Homes