Project Overview

Brick Kiln Bridge carries Willenhall Lane over the Wyrley & Essington Canal, part of the historic Birmingham Canal Navigations network in the West Midlands. This canal has shaped the industrial and social fabric of the region for over two centuries, originally built to link coalfields, quarries, and workshops to wider markets and towns. Even today, it is a treasured urban waterway, cleaned up and restored over recent decades, that provides a recreational haven, walking route, and cultural asset for communities in and around Walsall.

During planned concrete deck repairs, the canal’s continued navigability and public access beneath the structure were key stakeholder requirements, including from the Canal & River Trust. The Contractor appointed by the client to manage and undertake the works, CLM (Construction) Ltd, engaged Crafter Engineering to design a temporary works solution capable of safely supporting the bridge deck while preserving the character and ongoing use of this living waterway.

The Challenge

This project demanded a solution that balanced technical safety with real-world constraints:

Constrained vertical clearance beneath the bridge limited the scope for heavy propping systems.
Active canal navigation and towpath use needed to continue for the publicand leisure boaters.
Site logistics and access were restricted, ruling out large plant and extensive scaffold frames.
Sensitive setting, given the canal’s role in local heritage and community amenity.
Programme pressures, including canal-stage closure windows, created a narrow working window.

Had the temporary works been overdesigned, it could have imposed unnecessary restrictions on canal traffic or recreational use, undermining the very community value that makes waterways like this trusted urban assets.

Our Approach

Early involvement was critical. Working together, Crafter Engineering and CLM undertook a dimensional site survey and constructability consultation before concept design, ensuring an understanding not only of the structural requirements but also of canal use patterns and public expectations. This enabled a balanced solution that respected both engineering imperatives and the cultural value of the waterway.

Working collaboratively with CLM and the Canal & River Trust, we developed a bespoke ladder-beam based support system, prioritising minimal footprint and maximum flexibility.

The Solution

The design centred on a lightweight scaffold and ladder beam framework that:

Provided robust structural support to the existing concrete deck panels throughout demolition and repair.
Maximised navigable space beneath the bridge, keeping the canal open for boats and towpath users.
Allowed phased construction, so works could be staged panel by panel without restricting public movement.
Minimised plant requirements, using primarily man-handled components.

Key considerations included:

Setting ladder beams at depths that avoided unnecessary interference with canal clearance.
Designing the solution around site reality rather than textbook assumptions.
Using standard components in a bespoke arrangement to support adaptability on site.

The solution was meticulously detailed, but, importantly, designed with ease of installation and construction sequencing in mind, aligning with how CLM has carefully planned to execute the works. scaffold tubes and anchors, informed by site inspection and engineering judgement

Construction Support

Temporary works rarely unfold exactly as drawn when faced with real site variability. Crafter Engineering remained engaged throughout installation and repair operations, providing ongoing support to:

Respond to sequencing changes requested by the contractor
Advise on slight deviations in site conditions
Ensure that the temporary solution continued to align with both safety requirements and canal access commitments

Outcome

The project was delivered on time and within budget, with outcomes that extended beyond technical compliance:

Safety delivered without compromise, the structure remained stable throughout works.
Canal navigation and public access preserved for the majority of the programme, aligning with community expectations and stakeholder commitments.
Efficient installation and removal reduced downtime and disruption.
A practical, flexible temporary works solution that contributed to smooth site operations.

The canal continues to serve local boaters, walkers, and residents, not just as a transport relic, but as a revitalised part of urban life in Walsall.

Why It Worked

This project demonstrates the value of:

Early temporary works involvement, shaping methodology rather than reacting to it
Engineering judgement, not just calculations
Collaborative working, with designers embedded in the delivery team
Designing for construction, not just compliance

By focusing on how the works would actually be carried out on site, Crafter Engineering delivered a solution that was safe, practical, and efficient.

Crafter Engineering’s Role

Full temporary works design for deck support
Early-stage site survey and constructability alignment
Engineering judgement on load management and sequencing
Ongoing construction-phase engineering support

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Projects

Brick Kiln Bridge Refurbishment