For over 30 years, Carver Engineering has been specialising in the fabrication of steel bridge projects across the UK. Our critical expertise in these works has served as the backbone for many modern highway bridge infrastructures. Over the years, we have consistently delivered innovative solutions for providing safe connections over busy roads.
We have successfully completed many complex steel fabrication projects, often within challenging highway environments. This track record demonstrates our ability to meet strict deadlines, and ensure expert execution with minimal disruption. All of this has been met while maintaining the highest safety standards.
In this article, we will explore four of our most successful highway bridge fabrications over the years. These cases have required precise coordination and planning with our external teams and clients to meet each roadway’s unique requirements. Each project demonstrates how innovative steel fabrication drives successful infrastructure delivery.
1. White City Imperial College Overbridge
Working with Careys and completed in 2024, the White City Overbridge serves as a vital piece of infrastructure in the Imperial College campus in London. Connecting various facilities and providing more pedestrian and traffic access flows throughout the campus, the introduction of this overbridge has proved invaluable.
This project required the precise fabrication and coordinated installation of a 25 metre long steel bridge. The challenge was getting the bridge up and running during minimal possession hours and with utility integration for completion.
To mitigate the risks and ensure strict adherence to the proposed timeline, we successfully completed over 60% of the fabrications works off-site at our Doncaster facility. Here, we fabricated eight braced plate girders, soffit panels and pre-installed utilities within the girder assemblies to streamline the entire project. We also performed a trial erection at this point to ensure the new highway bridge was structurally sound and fit for purpose.
By arriving on-site with utility systems already built, this eliminated weeks of dangerous works over a live railway line. During scheduled possession hours, we used precision craneage to position the girders efficiently. Careys were able to come in after our work was completed to form the concrete deck. With that, the overbridge was completed on schedule, highlighting our ability to deliver complex highway structures with minimal disruption.
2. Etruria Link Bridge
In early 2022, we proudly completed fabrication works on one of the largest transport infrastructure projects in Stoke-on-Trent. The Etruria Link Bridge is a core connection point in the area, linking the A500 to Festival Park. The inclusion of this bridge to the local area has also successfully created hundreds of job opportunities for residents with a better access point to the Ceramic Valley Enterprise Zone.
Minimising on-site construction time was critical as we were both working closely with other trades on the SCAPE Framework and aiming to minimise traffic disruption. Once again, we utilised our facility’s capabilities to manufacture 21 braced pair weathering steel plate girders, conduct detailed trial erections, and apply advanced protective coatings to the structure. These coatings have future-proofed this structure against maintenance closures for painting.
With 800 tonnes of steelwork at play, we successfully transported the bridge in manageable sections ready for erection. Now, the bridge crosses both the West Coast Mainline, and the Trent and Mersey Canal. This isn’t just a bridge over a road, but crosses one of the busiest railway lines in the UK and a body of water.
By handling the heavy fabrication and trial assembly off-site, we allowed other trades to complete their works and installations without interruption for a streamlined process and uninterrupted timeline. The result is a quality, large-scale modular steel bridge that has enhanced the local area.
3. Peddimore Footbridge
One of our most challenging and large-scale highway installations was the striking 20 metres high arch structure Peddimore Footbridge over the A38 in Minworth. This piece faced extreme pressure. Not only were there challenging, record-breaking heatwaves, but an immovable deadline of the Commonwealth Games, held in Birmingham in 2022. This caused a three-week road closure embargo.
Our approach was to collaborate closely with Winvic to develop a precise installation plan. The bridge, comprising three deck sections and three arch segments, was fully fabricated and trial-assembled at our off-site facility. Once safely transported to Minworth, we successfully assembled the 90-tonne structure adjacent to the new roundabout which kept the traffic flowing.
Using two cranes to lift the structure onto six Self-Propelled Modular Transporters (SPMTs), we installed the bridge during a planned overnight closure to continue minimising traffic disruptions during peak hours. This method is highly specialised and allowed us to beat the timeline pressures and proved a better alternative than slowly lifting the bridge piece-by-piece.
The installation was completed ahead of schedule despite the extreme weather conditions and time pressures. This achievement stands as a testament to the flexibility, dedication, and reliability of our steel fabrication teams.
4. Newsham Overbridge
As part of the pivotal New Northumberland Line, the Newsham Road Overbridge was designed to replace an existing level crossing. Completed in January 2024, this steel bridge safely carries road traffic over the railway and connects South East Northumberland to Newcastle.
We began our work within months of project commencement, fabricating and trial assembling four plate girders and bracing beams in Doncaster with our top-of-the-range surveying equipment. This guaranteed that the bolts would line up correctly when we reached Newsham.
When the bridge was transported to our pre-assembly yard in Newsham, the pieces were, as predicted, successfully bolted into six braced pair assemblies.
With a tight 27-hour rail closure window, speed and accuracy were paramount for this project. We successfully installed all bridge items within possession hours, allowing our client Morgan Sindall to progress the formwork ahead of the bridge deck pour.
Following the deck formation, we completed the temporary works, jacking, and bearing installation to bring the bridge to a successful conclusion.
Why innovation matters in fabrication projects
What connects these four highway bridge projects is our commitment to solving high-stakes infrastructure challenges. Each project, from live railways to busy highways, successfully met tight deadlines and minimised traffic disruption. This was achieved by utilising specific engineering capabilities and leveraging the success of our off-site facility.
Whether it was pre-installing utilities at White City to save time, or using advanced surveying at Newsham to guarantee a fit during a tight 27-hour timeframe, our innovation lies in predicting site challenges and solving them before the steel leaves our facility.
Partner with Carver Engineering for highway bridge fabrication works
Choosing Carver for your next steel fabrication project means partnering with experts who are dedicated to successful execution and careful planning, every time.
Contact us today to learn more about how we can support your highway bridge projects.
