Lock gates might look timeless, as though they’ve always been built the same way. But behind the scenes, the craft of making them is constantly evolving.
Traditional age-old techniques being used to manufacture lock gates at Arden. Courtesy of National Waterways Archive
The imminent arrival of a new computer-controlled timber cutting machine at our Bradley lock gate workshop might sound like a clash between robotics and craft traditions. Far from replacing tradition, it is simply the next step in a long history of innovation, where each generation has adapted the craft to keep canals working.
As you may know, when engineering pioneers like Thomas Telford and William Jessop built our canals, there was no standard template for lock gates; they were simply constructed using the materials and methods different designers and engineers had to hand.
Today that means no two locks on our network are exactly alike. So, when lock gates need replacing – typically every 25 years or so – each one has to be carefully measured up and custom-made to meet the precise dimensions of the lock it serves.
For generations, this was done using rudimentary, hand-held tools, relying on the skill and dexterity of experienced craftspeople to shape individual gate components from oak timbers.
“We haven’t always made gates in the same way, though,” says workshops manager Simon Turner. “Although everything was done by hand initially, later the canal companies adopted steam-powered machines before moving on to electrical machinery in the middle of the last century. Now, after using these machines for decades, they are becoming obsolete, and we’ve reached another turning point.”
Craftsmen assemble lock gates at a yard in Hampton in Arden. Courtesy of National Waterways Archive
As Simon explains, time has taken its toll, and much of the machinery in our workshops is now 60 to 70 years old. That means we sometimes struggle to keep up with demand, as around 150 pairs of new gates need replacing each year.
Shaping the future of lock gate building
To ensure production keeps pace, we’re now investing in a ‘computer numerically controlled’ (CNC) machine. Custom-built by specialist fabricators in Europe, the new machine will be the largest of its kind in the UK.
Using digital designs and computer-controlled cutting heads, the machine will accurately shape and drill oak timbers, producing the components needed to build lock gates far faster and more efficiently than the ageing machinery it replaces.
The new CNC machine will improve productivity by 25%
We’ve got to embrace new technology in order to work as cost-effectively as possible and make the most of the money available to us,” says Simon. “We’ve never made gates in this way before; it’s an absolute first. After steam power and electricity, it’s the next big step in the evolution of lock gate production. It means the craftspeople can use their time and skills more productively where they are needed most.”
The investment in the new CNC machine is expected to boost production from around 150 lock gates a year to 190, an increase of more than 25%. And with demand expected to increase, it couldn’t come at a better time.
A rising wave of demand
We’re seeing a surge in demand for new lock gates, as many of those installed during restoration work in the 1990’s and early 2000’s, are now reaching the end of their lifespan.
This means that over the next few years, increasing numbers of gates will need to be replaced across the network- a ripple effect from that period of canal revival.
Thankfully, the new CNC machine will help our teams keep pace with this growing workload. By investing now, we’ll be able to produce more lock gates, quicker and cheaper, helping ensure our locks stay open, safe and usable for every boater who depends on them.
Blending tradition and technology
As our working practices evolve, it’s important to remember that these innovations will work in harmony with the age-old skills passed down for generations.
The new CNC machine will simply take over the bulk of the heavy cutting and shaping work, while our skilled workshop teams continue to assemble, fit and finish every gate by hand. It's a blend of old and new: centuries-old craftsmanship supported by cutting-edge technology.
It's a practical investment in the future that will help ensure lock gates can continue to be replaced when needed, keeping canals open, safe and navigable for another generation and the millions of visitors who enjoy them every year.
If you’d like to see this craftsmanship up close and learn more about how lock gates are made, why not join Simon for one of our upcoming online talks? He’ll explore the fascinating history of lock gate production, reveal the construction techniques and materials involved, and discuss the differences between gates on various canals. Sign up today for a unique insight into the remarkable craftsmanship that has kept our canals moving for generations.
