Repairing a two-tonne stone beam in the heart of the Pennines

Storm damage to a stone beam weighing more than two tonnes forces a hiking path closure – repair commissioned by Yorkshire Dales National Park Authority in Colden, West Yorkshire.

Following a storm, part of an ancient stone footbridge on the Pennine Way was badly damaged when a tree fell and broke one of the main stone beams across the stream. The crossing had to be closed causing walkers to take a long detour.

The challenge

When Stress’ Goldhawk Bridge Division were appointed to assess a failing stone beam bridge on the Pennine Way, it quickly became clear that this was no ordinary structural repair. The bridge sat at the bottom of a steep valley, half a kilometre from the nearest vehicle track, accessible only via a narrow, winding path down treacherous valley sides. No cranes. No vehicles. Not even a quad bike could reach the site. Every piece of equipment including the scaffolding, hoists, hand tools, and materials, had to be carried in by hand across the challenging and remote West Yorkshire terrain. From the outset, logistical complexity was as significant an engineering problem as the structure itself.

Assessing the structure

At the centre of the storm damage was a single stone beam spanning 2.5 metres in length and weighing in excess of two tonnes. The beam had fractured, leaving the crossing compromised and the surrounding historic masonry at risk of further deterioration.

• Solution avoided full stone replacement
• Cost-effective methods
• Minimal environmental impact
• Reduced programme duration
• Retained original historic material
• Britain’s first official National Trail the “backbone of England”

An engineered solution

Replacement was considered and ruled out as wholly impractical. However, a closer inspection revealed a significant advantage; the stone had fractured cleanly into two distinct halves. This presented an opportunity to design a technically robust repair rather than a full replacement, relieving the complexity of mobilising specialist lifting equipment to such an inaccessible location.

Engineering and material science

• Manual mobilisation of all plant, scaffolding, and materials across 0.5km of rough Pennine terrain
• Extraction of both stone halves from the stream bed using manually operated hoisting equipment
• Thorough cleaning and drying of the fracture faces to ensure full bond integrity
• Precision drilling to accept large-diameter stainless steel pins, providing mechanical reinforcement across the joint
• Structural re-bonding of the two halves using a high-strength epoxy resin system, restoring full load-bearing capacity
• Reinstatement of the repaired beam, hoisted back into its original position and anchored securely to the
  masonry abutments

The outcome

The reinstated beam restored structural continuity to the crossing, preserving an historic rural structure in situ, at a fraction of the cost and environmental impact of replacement. The project stands as a clear example of what experienced structural engineering judgement, combined with careful on-site execution, can achieve even in demanding conditions.​​​​​​​​​​​​​​​​

This innovative and cost-effective procedure meant the Pennine Way crossing at Colden was reopened at a public ceremony with the local Mayor, Morris Dancers, representatives of Stress’ Goldhawk Division and a gatherig of keen hikers. Celebrations were hosted by the local New Delight Inn.