Steel kerb lintel replacement for heavy vehicle corners
- Galvanised steel lintel that replaces concrete lintels broken by trucks and buses, without rebuilding the pit and kerb.
- Fitted to the existing drain in 1 to 2 hours, depending on the site.
- Straight or radial, made to measure to suit any pit type and kerb profile.
- Australian Innovation Patent No. 2019100358.
- Designed and made in Unanderra, NSW.
Price: 2.4m lintel from $1,900 ex GST supply only, or $4,900 ex GST supplied and fitted. Price subject to location. A typical Sydney installation is $6,900 supplied and installed, due to travel.
Lead time: 2 to 3 weeks from order.
See it installed
A concrete lintel on a tight-radius corner at Dapto, broken again by heavy vehicles, replaced with an ENCAT steel lintel in about an hour. Read the full project.
BUILT FOR TRUCK AND BUS WHEEL LOADS OVER 30T
FACTORY DIRECT, MADE IN UNANDERRA, NSW
DELIVERED ANYWHERE IN AUSTRALIA
MADE TO SUIT THE EXISTING PIT AND KERB
- Ends repeat repairs: one installation replaces the cycle of concrete lintel replacements at corners where heavy vehicles clip the kerb.
- Fast to install: 1 to 2 hours on site, which keeps crew time and traffic control to a minimum.
- Anti-lift design: resists the lifting force created when truck wheels rub against the face of the lintel.
- Safer for pedestrians: checkerplate anti-slip top surface, and no broken concrete exposing the pit opening.
- Water flow is unaffected: no concrete debris falling into the pit and blocking the inlet.
- Fits the existing pit and kerb: gully pits, kerb inlet pits and side entry pits, and barrier, semi-mountable and roll-over kerbs.
No# 2019100358
We designed this lintel after seeing the same problem at council sites over and over. A concrete lintel on a tight corner is broken by a truck or bus. It is replaced with another concrete lintel, and within a short time it is broken again.
Concrete lintels are designed for the loads of a standard kerb. At some corners, heavy vehicles run over the kerb as a matter of routine because the road is narrow, the corner radius is tight, or traffic and street furniture leave no room for a wide turn. The wheel loads are higher than the precast lintel can take. It cracks, and the broken pieces fall into the pit.
Putting another precast lintel back into the same conditions gives the same result. That is why repairs at these sites rarely last.
Our steel lintel is built for the loads that actually occur at those corners. It has been installed at over 100 sites since 2019 with a 100% success rate.
“With the ENCAT lintel, once it’s mounted, it’s the end of the problem. There’s no more damage. There’s no more repairs.” John Ford, Engineer and Director, ENCAT
Why kerb lintels keep breaking, and what repeat repairs cost councils
When to use a steel lintel
Concrete lintels are fine for most streets. Steel is the better choice where heavy vehicles regularly drive over the kerb.
| Site | Recommendation |
|---|---|
| Standard residential street with no history of lintel damage | A concrete lintel is usually sufficient |
| Corner or verge where the lintel has been broken more than once | ENCAT steel lintel |
| Bus routes and freight routes with tight turns | ENCAT steel lintel |
| Industrial areas with heavy haulage | ENCAT steel lintel |
| Change in traffic use, such as a new development or rerouted bus service | ENCAT steel lintel at the affected corners |
How it works
The lintel is fitted to the existing drain, so the pit and kerb do not need to be rebuilt. The existing broken lintel stays in place, and the drainage system is unaffected. Think of it as a heavy duty steel cover plate that fits snugly over the concrete lintel.
It is bolted down onto the existing lintel and gutter with stainless steel chemset fixings. The top fixings are countersunk so they do not create a trip hazard.
Council staff often ask: “If we ever need to get into the drain, can it be removed?” Yes. It can be removed by unbolting it.
Fits your existing pit and kerb
Every ENCAT lintel is measured and made for the site, so it suits the pit and kerb that are already there.
- Pit types: gully pits, kerb inlet pits and side entry pits, including pits with an extended kerb inlet (EKI).
- Kerb profiles: barrier, semi-mountable and roll-over. Any kerb profile can be upgraded.
- Shapes and sizes: straight or radial, any length or opening.
A steel alternative to replacing the concrete lintel and pit
When a precast concrete lintel breaks, the usual fix is to break out the lintel, and often the top of the pit and kerb, then form up and pour or set a new concrete unit. That means excavation, formwork, curing time and days of traffic control. At a problem corner, the new concrete lintel is then broken again by the same trucks.
The ENCAT lintel is the alternative. It fits over the existing concrete lintel, so the pit, kerb and drainage stay in place, and the site is reopened in 1 to 2 hours.
Comparing the options, or need steel approved where your standard drawing specifies precast? Read A steel alternative to precast concrete kerb lintels.
Why broken lintels need fixing quickly
- Broken concrete can expose the pit opening, creating a trip and fall hazard for pedestrians.
- Debris falls into the pit and reduces how much water the drain can take, which can lead to local flooding in heavy rain.
- Loose pieces of concrete can end up on the road.
- Material: Steel
- Finish: Hot dip galvanised
- Welding: Certified welding to AS/NZS 1554.1
- Top surface: Checkerplate, anti-slip
- Colour: Silver, to blend with the concrete guttering
- Lengths: Custom made to suit each drain
- Shapes: Straight or curved, any length or opening
- Pit types: Gully pits, kerb inlet pits, side entry pits, extended kerb inlets (EKI)
- Kerb profiles: Barrier, semi-mountable, roll-over. Any kerb profile can be upgraded.
- Load rating: Class G, over 30 tonne wheel load
- Weight: 50 to 100kg
- Installation time: Typically 1 hour, up to 2 hours depending on site conditions
- Lead time: 2 to 3 weeks
- Patent: Australian Innovation Patent No. 2019100358
- Also known as: Kerb inlet lintel, stormwater lintel, drainage lintel, pit lintel, EKI lintel, letterbox head
How installation works
- Send us the site details. Photos of the damaged lintel, the length of the drain opening, and whether the kerb is straight or curved.
- We make it to suit. Each lintel is measured and manufactured for the site in 2 to 3 weeks.
- We install it. We set up traffic control, cut away the broken concrete, mount the ENCAT lintel over the concrete lintel, then drill, chemset and bolt it down, clean up and leave the site.
Typical time on site is about an hour. Download the installation guide (PDF).
What we need for a quote
- Location: site address or nearest intersection
- Photos of the damaged lintel
ENCAT has designed and manufactured civil infrastructure in Unanderra, NSW since 1989. Design, engineering and fabrication are all done in-house, so we can make lintels to suit unusual sites without outsourcing.
- Lintels supplied to councils and state and federal road authorities
- In-house design and engineering, led by founder and engineer John Ford
- Local manufacturing with certified welding
- Delivered anywhere in Australia
The cost of a lintel that keeps breaking
The price of one concrete lintel is not the real cost. At a problem corner, the cost is every replacement, every crew visit and every traffic control setup for the broken lintels. Every corner is different. How often a concrete lintel breaks depends on the volume of traffic and how much of it is trucks and buses. Where truck and bus traffic is high, a concrete lintel is often replaced several times a year.
| At a corner with high truck and bus traffic | Concrete replacement | ENCAT steel lintel |
|---|---|---|
| Cost per replacement, supplied and fitted | $14,900 | $4,900 |
| Replacements in a year | 3 or more | 1 |
| Total in the first year | $44,700 or more | $4,900 |
See the full cost breakdown and how to identify sites worth upgrading.
Related products, projects and guides
Frequently asked questions
How much does a steel kerb lintel cost?
A standard 2.4m ENCAT steel lintel is $1,900 ex GST supply only, or $4,900 ex GST supplied and fitted, subject to location. Other lengths and curved lintels are quoted to suit the site.
Is a concrete or steel stormwater lintel better?
Concrete stormwater lintels are fine for most roads. Where heavy vehicles regularly clip a corner or verge, a steel lintel is the better choice because it is built for those wheel loads and will not crack the way precast concrete does.
What load can the lintel take?
In excess of 30 tonne wheel load.
Does the lintel fit an existing drain?
Yes. It is designed to be fitted to the existing drain, so the pit and kerb do not need to be rebuilt. It suits gully pits, kerb inlet pits and side entry pits, and any kerb profile.
Is it an alternative to replacing the whole concrete pit and lintel?
Yes. Instead of breaking out and rebuilding the concrete lintel and pit, the ENCAT lintel is fitted over the existing lintel in 1 to 2 hours. The pit, kerb and drainage stay as they are.
Can it replace an extended kerb inlet (EKI) lintel?
Yes. Each lintel is made to the length and opening of the pit, including gully pits with an extended kerb inlet.
Can we use it where our standard drawing specifies a precast lintel?
Many council drawings specify a precast concrete lintel “or as approved” or “or equivalent approved by Council”. That wording allows an alternative product that matches the kerb, so the ENCAT lintel can be put forward for approval. See how to get a steel lintel approved.
How long does installation take?
About an hour on site for a standard installation. Traffic and pedestrian control is also needed for each installation.
Can you make curved lintels for corners?
Yes. Radial lintels are measured, designed and made to suit the kerb radius at each site.
Can the lintel be used on council and state roads?
Yes, the lintel is suitable for all roads.
Do you supply and install outside NSW?
We deliver anywhere in Australia.
Is there a warranty?
Yes. A 100% money back guarantee if the lintel fails in service.