Brickwork – How to Create an Opening

Safety First

How to create an opening for Brickwork? Before you begin, make a list of all the materials you’ll need for the job. Most importantly, don’t forget a small scaffold—it’s essential for working safely at height. For best results, use two steel trestles with three or four scaffold boards. Additionally, if you can, install a handrail at the back of the scaffold to prevent falls. Remember, even at low heights, falls occur frequently, so take every precaution to work safely.

Now, let’s take a moment to shamelessly promote our Butlins Maxi Trestle—and for good reason. We designed it specifically for low-height work after seeing how many injuries happen in those conditions. Not only is it height-adjustable, but its legs also adapt to uneven terrain or steps. Furthermore, the trestle folds down to just 47 cm, opens up to 90 cm, and includes an optional handrail. Despite its features, it takes up very little storage space and weighs only 10 kg. In short, every tradie and DIYer should have a set.

Step 1: Plan the Placement

Now that safety’s covered, let’s get back to the task at hand. First, decide exactly where you want the opening in the brickwork.

Next, install a galvanised steel or concrete lintel above the planned opening. This will carry the load of the wall above. Always install the lintel before removing any bricks.

• Use a steel lintel if the finished wall will be exposed face brick.

• Use a concrete lintel if you plan to render the wall.

Step 2: Set Up Maxi Props for Propping

You’ll need steel Maxi props and either:

• 125 x 50 mm timber needles, no longer than 2.4 m, or

• Strongboy attachments, which I recommend.

Why Strongboys?
You’ll use half as many props, won’t need large holes, and can slot them between bricks by simply removing the mortar. We’ll use Strongboys in this guide for efficiency.

Before inserting the props, check if the floor can support the load.

• A concrete floor usually holds up fine.

• If working on a timber floor, remove boards to inspect the joists and strengthen the area if needed.
  Regardless of floor type, always use a timber plank beneath each prop to spread the load.

Step 3: Install the Props with Strongboys

To begin, decide exactly where to insert the Strongboys into the brickwork. Next, use a power drill and masonry bit to remove the mortar between the brick joints. Carefully drill just enough to allow the attachments to slide in. However, if they don’t fit, you may need to remove a brick from below.

For optimal support, space the Strongboys no more than 90 cm apart—although 60 cm is preferred for greater stability in load-bearing brickwork.

Once spaced correctly, insert the Strongboys into the brickwork wall and secure them to the Maxi props. Then, tighten the handles to transfer the load of the wall onto the props. At this point, you’ll see why Strongboys offer a more convenient solution—you only need them on one side of the brickwork, which significantly improves ease of movement and access.

By contrast, using needles would require twice as many props, twice as many planks, and considerably more setup time.

Step 4: Remove Bricks for the Lintel

Once the props are securely in place, start removing the bricks where the lintel will sit. You have a few options here:

1. Angle Grinder – Use a 9-inch grinder with a diamond blade to cut the mortar. This method creates a lot of dust and suits full refurb projects.

2. Masonry Drill – Drill out the mortar using a masonry bit, working side to side.

3. Chisel and Hammer – Use a bolster chisel and club hammer for precision.

Once bricks are removed, install the lintel. If you have concerns about the masonry, use engineering bricks for the bearing points. The lintel must extend at least 150 mm (6 inches) past each side of the opening.

For internal openings, choose reinforced concrete lintels.
You may need to remove another course of bricks beneath the lintel to set it in the correct position.
Apply a mortar bed to the bearing points and on top of the lintel. Then place the lintel and check that it’s level.

Allow at least 24 hours for the mortar to cure before moving forward.

Step 5: Final Steps – Remove Props and Create the Opening

Once the mortar sets and the lintel is solid, remove the Maxi props and fill the Strongboy holes with mortar.

Now it’s time to remove the bricks below the lintel. Always start from the top and work down. If you need to cut bricks, use a chisel from above and support bricks underneath with those below.

Personally, I prefer using a grinder with a diamond blade to cut the full opening—it’s cleaner and faster, though not always suitable, especially in occupied homes. In such cases, remove each brick manually using a chisel and hammer.

Always wear safety goggles, gloves, and steel-toe boots while working.

You Now Have Your Opening

With the lintel secure and the opening fully cut, your job is done. You’ve successfully and safely created an opening in the brickwork—supported by Maxi props, backed by proper tools, and most importantly, done without compromising safety.

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