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Otley Bridge Footway Cantilever Steelwork
Cairnhill was appointed by Balfour Beatty to manufacture and install a new steel footbridge alongside the historic Otley Bridge, a landmark structure dating back to 1229. The £745k project was delivered over an intensive 14-day programme, the project required specialist lifting, meticulous planning, and close coordination to safely integrate the new bridge within a live highway and heritage environment.
Cairnhill was appointed by Balfour Beatty to deliver the manufacture and installation of a new steel footbridge at Otley Bridge, a historically significant structure dating back to 1229. The £745k project was delivered over an intensive 14-day programme, operating across both day and night shifts, and required a high level of technical expertise, planning, and coordination due to the sensitivity and importance of the existing structure.
Working from the client’s detailed design, Cairnhill was responsible for the full manufacture and installation of the new footbridge, which was constructed alongside the existing road bridge. Given the age and heritage status of Otley Bridge, careful consideration was required at every stage to ensure that the new works were integrated safely and sympathetically without compromising the integrity of the historic structure. Close collaboration with Balfour Beatty was maintained throughout the project to manage risks and align on sequencing, access, and programme constraints.
One of the key technical challenges was the installation of seven individual bridge spans onto the existing stone piers. This operation required the use of a 450-tonne crane, with all lifting activities planned and executed by Cairnhill’s specialist lifting team. The presence of live services on the piers added further complexity, necessitating the design and installation of engineered temporary works to support the services throughout the lifting operations.
This approach allowed the new steel spans to be carefully positioned beneath the services while suspended from the crane, after which each span was bolted together in a strictly controlled sequence. This method ensured that other trades could promptly and safely reinstate the services once each lift was completed.
All structural components, including the steel bridge spans, deck plates, and handrails, were fabricated off-site at Cairnhill’s facilities. To maximise quality and durability, the steelwork was fully painted off-site using a specialised four-coat protective paint system. The deck plates were also pre-finished with a Thorgrip anti-slip surface, providing a robust, long-lasting, and safe pedestrian walkway upon installation.
Site installation was carried out entirely by Cairnhill’s in-house teams, including experienced steel erectors, specialist lifting personnel, and paint technicians. This ensured full compliance with stringent highway and safety standards while maintaining tight control over quality and programme.
The works were delivered under strict traffic management arrangements, including full road closures, and required careful coordination of day and night shifts to minimise disruption to the local community and maintain progress against the challenging programme.
Despite the technical, logistical, and operational complexities associated with working on a historic structure within a live highway environment, Cairnhill successfully completed the footbridge installation on schedule. The project was handed over to the client in time for opening, delivering a high-quality, durable pedestrian crossing that complements the existing bridge while meeting modern safety and performance requirements.
