How we bring your wrought iron gate to life in 6 key stages

A wrought iron gate is more than just an entrance; it’s a statement of style, security, and craftsmanship. Whether you’re after a timeless classic or a modern showpiece, the process of bringing your vision to life requires skill, precision, and a deep understanding of metalwork – and that’s exactly what we provide right here at North Valley Forge. Every gate we create is made to order, which means that each one is tailored to suit your individual taste and requirements. As you might imagine, it’s a fairly involved process – so in case you’re curious, here’s a bit more of an in-depth look at the six key stages that take your gate from concept to completion.

1. Design process

At North Valley Forge we’ve always been proud to offer a broad selection of designs on our website, encompassing everything from sleek and minimalist to intricate and ornate. Whether you’re drawn to the elegance of traditional scrollwork, or prefer a contemporary aesthetic, rest assured you’ll always be able to find a style that suits your property.

You can choose a gate exactly as it appears on our site, or even make some alterations to it to suit your own style – we can modify an existing design or create something entirely bespoke. We make all of our gates to order, so our team will be able to easily make your vision into a reality. If you’re still finalising the design, or you need a bit of assistance, we’re more than happy to help. With more than 30 years of experience behind us, we’ve got an excellent track record, and we love a good challenge!

2. Measuring and producing CAD drawings

Once we’ve established your requirements, we move on to the next step – ensuring that the measurements and technical details are correct.

• If possible, we’ll visit your property to take precise measurements and conduct a full site survey.
• If an in-person visit isn’t possible for whatever reason, we can work with dimensions and images that you provide to create an accurate plan.
• After assessing the site, we’ll advise on the best fixing methods and talk you through the project’s management process.

Once your order is officially placed and payment is received, our CAD engineers will produce detailed design drawings. We’ll create these technical drawings using exact scaled dimensions, so that we can provide a clear representation of what the final gate will look like. Once you’re happy with the design, we send the approved drawings to our fabrication team – and that’s where the real magic begins!

3. Fabrication

All of our ironwork is handcrafted in our factory and headquarters in Nelson, Lancashire. Here, we use a combination of age-old blacksmithing techniques with modern machinery, ensuring that each gate meets our exacting standards. Attention to detail is one of the distinguishing features of our craftsmanship, and we maintain consistently strong standards across every piece we produce.

Part of this process includes hot dip galvanising, a crucial step that protects the metal from corrosion. This process involves dipping the gate into molten zinc at approximately 450°C, creating a fully bonded protective layer that prevents rust. The zinc coating forms a barrier against moisture, oxygen, and other corrosive elements, dramatically extending the lifespan of your gate. This prevents it from being highly susceptible to rust, especially in outdoor conditions where rain, frost, and pollution can take their toll. This process ensures that your gate remains strong and durable for decades with minimal maintenance.

After galvanising, we’ll then move on to powder coating – it’s another major part of the finishing process. Basically, it provides an even, tough, and highly resistant surface that stands up to wear and tear far better than traditional paint. Unlike liquid paint, which can chip, crack, or peel over time, powder coating is applied as an electrostatically charged dry powder and then cured under heat to create a smooth, hard-wearing finish.

There are several advantages to this, including (but not limited to):

• Improved durability. Powder coating resists UV rays, moisture, and general weathering, preventing the finish from fading or deteriorating over time.
• Better protection. It creates a strong shield over the metal, reducing the risk of scratches, chipping, and environmental damage.
• Customisation. Our standard finishes are black and anthracite grey, but we can powder coat your gate in any RAL colour you choose. (RAL colours are a European colour matching system, ensuring precise and consistent shades.)

Essentially, powder coating helps ensure your gate remains in excellent condition while also giving it a clean, professional finish.

4. Finishing

This stage is all about refining the final look of your gate. After painting, we can enhance the detailing with patinas, which involve lightly brushing gold, silver, or bronze over the surface contours. This technique highlights intricate features, giving the gate added depth and elegance.

For a simpler look, we can leave the ironwork with a plain painted finish. However, if you’re looking for something more extravagant, you can also choose Everlasting Gold paint. We can use this for key details, such as railheads and decorative elements, fully coating in a rich, golden hue for an opulent touch.

For our hardwood gates, we apply UV protective coatings. These coatings help preserve the natural beauty of the wood while protecting it from fading and the effects of weather exposure. They also enhance the grain, leaving them with a glossy, polished finish.

5. Installation and testing

Once the fabrication and finishing processes are complete, we can then move on to installation. As accredited members of Gate Safe and the Door & Hardware Federation (DHF), we provide a full installation service, covering everything from groundwork to intercom system setup.

If you choose automation for your gates, this is the point at which we carry out a series of essential safety tests before completing the installation. These include force testing and CE marking, ensuring that your gate meets all safety regulations. We’ll also provide guidance on the necessary safety edges and photocells required for your specific gate type – so that you can be sure that your gate will provide safety, security and peace of mind.

6. Aftercare

If you’ve chosen to automate your gates, we can provide a Handover Pack after installation. This includes all site risk assessment details, documentation on the testing procedures, and important safety information.

Every automated system we install comes with a 12-month parts and labour warranty from the date of completion. If you want to keep your gate in peak condition, we also offer Gold and Silver service plans for regular maintenance. While servicing is optional, we strongly recommend an annual maintenance check to prolong the lifespan of your gate and ensure its continued performance. We can provide any additional explanations or details you might need on either one – feel free to ask!

Those are all the key points covered! And if wrought iron gates and railings are something you’re considering for your own property, we’d be delighted to help here at North Valley Forge. With over 30 years of experience in crafting stunning electric wrought iron gates, we have all the expertise needed to guide you every step of the way.

You can request a brochure to explore our ultimate collection, featuring stunning wooden gates, ironwork, and our latest aluminium and composite gate designs. Or if you prefer to chat on the phone, give us a call at 01282 677300, and our friendly team will be happy to assist you in any way we can.