Brooks Forgings Ltd is proud to announce its crucial involvement in the £17 million restoration of the Newport Transporter Bridge. Designed by the French engineer Ferdinand Arnodin, this Grade I listed structure, built in 1906, features a suspended gondola that transports vehicles and passengers across the River Usk without obstructing the passage of tall ships. It is one of only six operational transporter bridges left in the world, and the largest and oldest among them.
During extensive inspections, it was found that the cable tensioning system components on the bridge's main horizontal boom needed to be replaced. The boom is a stiffening girder designed to support the weight of the moving "traveller" and the gondola below.
Brooks Forgings was approached by the lead contractor to produce 256 replacement U-bolts for the cable tensioning systems. The U-bolts are made from 1-inch (25.4 mm) diameter 708M40 (EN19) alloy steel, heat-treated to a T-condition to provide the necessary high tensile strength and fatigue resistance for handling dynamic bridge loads.
Brooks Forgings Ltd manufactured 256 replacement U-bolts for the cable tensioning systems found on the Newport Transporter Bridge.
The U-bolts begin as threaded studs measuring 1532 mm overall, with 480 mm of 1"-8 UNC (Unified Coarse) threading on each end. Localised induction heating is used to heat the midpoint of each stud, which is then bent using specialised equipment and force-dissipating tooling to achieve a 45.5 mm inner bend radius. This method ensures a perfect fit without flattening or reducing the diameter of the raw material.
Threaded studs measuring 1532 mm overall, with 480 mm of 1"-8 UNC (Unified Coarse) threading on each end.
Localised induction heating is used to heat the midpoint of each stud.
Specialised equipment and force-dissipating tooling is used to achieve a 45.5mm inner bend radius.
The warm formed u-bolts in 708M40 EN19 material prior to the galvanising process.
To protect against the aggressive saline environment of the Severn Estuary, each U-bolt is hot-dip galvanised in accordance with BS EN ISO 1461:2009.
Each U-bolt is supplied with pairs of UNC full nuts, half-locking nuts, and washers, providing a complete solution from one approved source.
A 3D render of the Newport Transporter Bridge showing the placement of the new u-bolts within the tensioning system.
A 3D render showing the tension system configuration at each fixing point along the boom. The U-bolts fit over 90mm diameter pins.
As the restoration project approaches its expected completion in late 2026, Brooks Forgings is honoured to have contributed its metal forming expertise to this significant project. Our components now form an integral part of the bridge's structure, ensuring its enduring presence across the Usk for generations to come!
