Carver Engineering is proud to announce the successful completion of the fabrication works at St Catherine’s Wood as part of the Victoria North project in Manchester.
After five months of hard work and collaboration with our clients, the project was completed as scheduled in July 2026, with Carver creating and installing a range of bespoke metalwork designed to complement the natural woodland surroundings.
In this case study piece, we’ll explore Carver’s involvement in the project, our crucial preparation work in our steel fabrication workshop, and how we successfully tackled any challenges along the way.
St Catherine’s Wood: Project overview
For this project, we were contracted to fabricate the following structures:
- Stair walkways with galvanised open mesh flooring and stainless steel handrails leading to the top of the woodland area
- Gabion fencing for functionality and aesthetics surrounding the area, with over 1300 metres of flat bar utilised for the fabrication of the fencing
- Bespoke gates at the entrance to the park, with each of the three panels weighing over 360kg and standing at 50mm thick
The aim of the project was to provide functional access and safety fencing throughout the woodland space while blending in with the natural environment for members of the public to enjoy and explore the woods for years to come.
Precision workshop assembly
Once we received the materials we needed, our steel fabrication workshop was in full swing to prepare and work on the staircase, fencing, and gates simultaneously.
During the materials processing step of our work, we utilised water jet cutting to shape the large, intricate gates. Given the size and scale of the structure, this process was presented as the only viable option, as the 50mm thick steel, combined with the elaborate detailing, would exceed the limitations of our usual methods, such as laser or plasma cutting.
It was crucial for the gates to the woodland to be cut precisely in order to create thin bars that complement the woodland setting and allow visitors to easily see the greenery beyond them.
To guarantee smooth on-site installation, we conducted a comprehensive trial assembly of the large gates and supporting steelwork in our facility.
Trial erections are a critical aspect of our fabrication process, allowing our engineers to perform rigorous quality control checks, verify dimensional accuracy and tolerances, and ensure the structural alignments and joints are exact. By managing this in our controlled workshop environment, we eliminate any guesswork on-site, and save valuable time ahead of the project delivery.
We also welded the components of the staircases and fences together to form secure structures as part of the project, complete with non-destructive testing to confirm the longevity and durability of the frameworks.
Preparing steel structures for a woodland environment
The Victoria North project also presented a unique opportunity and task to our team – fabricating steel structures that blend beautifully into the green environment of St Catherine’s Wood, while simultaneously providing a durable and practical solution for visitors.
In response, we met our client’s project specification to finish the staircases and gabion fencing with red oxide paint. The earthy-toned coating helps the structures to both blend into the space, and provide an anti-corrosive protective finish that should prevent the steel from rusting over time.
On-site installation
Once all of the quality checks and inspections were complete and successfully passed, all of the components for the gates, staircases, and fencing were transported over to St Catherine’s Wood.
Our experienced site installation team carefully maneuvered the massive steel gates and other structures into their positions. They ensured the heavy elements were securely anchored and perfectly aligned, as per the detailed 3D CAD design.
Following the successful on-site installation of the three steel structures, Carver’s work on the Victoria North project was completed.
Project challenges & achievements
Despite our rigorous checks and trial assembly, we identified an unforeseen potential issue with the long-term functionality of the huge gates.
When the massive 360kg gates were installed and sitting under their own heavy weight, we discovered that if both the right-hand and middle gates were open at the same time, it would put an immense amount of strain and weight on the middle column.
Our team had to propose a solution on-site – our recommendation was to add an extension of the fabricated box section up to the top of the frame. Once approved, this modification provided essential rigidity, significantly reducing the possibility of the post excessively moving. Otherwise, this would have created huge stress on the structure that may have presented a health and safety risk in years to come.
Managing such huge and heavy steelworks for use in a delicate natural environment can be marked as a massive success for the Carver team. With our operation and processes needing to ensure accuracy and strict safety adherence throughout, we delivered another fabrication project in time and in accordance to the brief!
Bringing St Catherine’s Wood to life
It was a real pleasure to contribute to a project that will allow members of the public to enjoy and explore St Catherine’s Wood for years to come, providing a welcome place to connect with nature as the surrounding neighbourhood continues to grow. We’re proud to have played our part in bringing this fantastic space to life.
The space is now officially open to the public for the people of Manchester to enjoy!
Start your next project with Carver Engineering
Ready to begin your next steel fabrication project? Carver Engineering is here to help and become your partner to deliver exceptional results. No matter the structure requiring expert fabrication, we have the experience and expertise to bring your project to life.
To learn more about our services, contact Carver Engineering today or take a look at our most recent projects here.
