Grand Haven Pier Catwalk Restoration

ClientCity of Grand Haven
Project TypeHistoric waterfront restoration
Scope53 replacement catwalk bents
ServicesDesign, fabrication, transportation & installation
Fabrication Detail11,000+ custom-machined decorative rivets
LocationGrand Haven, Michigan
Featured Project

Recreating an Iconic Piece of West Michigan History

The Grand Haven South Pier Catwalk is one of West Michigan's most recognizable landmarks and an important part of the community's identity. When the aging catwalk required replacement, The Blacksmith Shop was selected to help recreate the structure while preserving the historic appearance that generations of visitors associated with the pier.

Working for the City of Grand Haven, our team designed, fabricated, transported, and helped install 53 replacement catwalk bents that closely matched the original structure while supporting long-term durability and performance.

The project became one of the largest and most complex fabrication efforts in company history, combining engineering, custom fabrication, transportation logistics, waterfront installation planning, and historic preservation considerations.

Grand Haven Pier Catwalk restoration metalwork at sunset
Project Scope

Custom Design, Fabrication, Transportation & Installation

The project required recreating 53 of the catwalk's 59 historic bents while maintaining the appearance, symbolism, and character that made the structure an important part of Grand Haven's waterfront.

  • Design and engineering of replacement catwalk bents
  • Fabrication of every bent assembly component
  • Creation of more than 11,000 custom-machined decorative rivets
  • Transportation from Greenville to Grand Haven
  • Barge loading and waterfront installation logistics
  • Installation of replacement catwalk assemblies
Project Priorities

What the Project Needed to Accomplish

The restoration required balancing historical accuracy, engineering complexity, fabrication quality, and real-world installation challenges.

Historic Accuracy

Thousands of hours were invested to recreate the appearance of the original catwalk while preserving an important community landmark.

Complex Fabrication

Each bent required extensive engineering, fabrication, and more than 100 hours of welding to achieve the required level of detail.

Waterfront Installation

Completed assemblies were transported across Michigan and loaded onto barges for installation along the Lake Michigan pier.

The Challenge

Preserving a Landmark While Building for the Future

Custom metal fabrication used for restoration work

The original catwalk was an important symbol of Grand Haven, but decades of exposure to Lake Michigan's waterfront environment had taken a toll on the structure. Community members raised more than one million dollars to support the restoration effort after the catwalk was excluded from the U.S. Army Corps of Engineers restoration project.

The replacement work required balancing historical authenticity with practical fabrication, transportation, and installation realities. Even the decorative rivets used throughout the original structure were recreated through custom machining to preserve the visual character of the catwalk.

Execution

From Engineering and Fabrication to Waterfront Installation

The project required thousands of engineering hours and extensive fabrication planning before production could begin. Every bent assembly was manufactured in Greenville, Michigan before being transported to Grand Haven for installation.

Once delivered, the assemblies were loaded onto barges and transported along the pier to support installation access. The completed catwalk was finished in time for the Coast Guard Festival, ensuring this important community landmark remained part of the Grand Haven waterfront experience.

The Blacksmith Shop fabrication work
Client & Location

City of Grand Haven

Completed in 2019, this project required custom design, fabrication, transportation, and installation support for one of Michigan's most recognizable waterfront landmarks.

Project Details

Planning Considerations for Similar Work

Large-scale restoration and civic projects benefit from detailed documentation, early engineering review, and clear coordination around transportation, installation, and existing conditions.

Photos, drawings, historical references, existing components, field measurements, and appearance requirements help establish how closely replacement fabrication must match original conditions.

Projects involving custom assemblies, decorative elements, engineering review, or historically significant structures often require extensive planning before fabrication begins.

Waterfront projects, restricted-access sites, public environments, and unique installation conditions may require specialized transportation and field execution planning.

FAQ

Project Questions

These answers explain how this featured project relates to similar civic, restoration, and custom fabrication opportunities.

Can similar restoration metalwork projects be reviewed?

Yes. Restoration and replacement-related fabrication can be reviewed when sufficient information is available regarding existing conditions, historical requirements, project scope, and installation needs.

What information is helpful for a civic or restoration project inquiry?

Helpful information includes drawings, measurements, photos, project location, site conditions, appearance requirements, target timing, installation considerations, and any available historical documentation.

Do you support transportation and installation planning for complex projects?

Project-specific transportation, delivery, staging, and installation requirements can be reviewed whenever they are part of the project scope and necessary for successful completion.

What made this project unique?

The project required recreating 53 historic catwalk bents, producing more than 11,000 custom decorative rivets, coordinating waterfront installation logistics, and preserving one of West Michigan's most recognizable public landmarks.