Behind the great first impression of the 6'5" tall goalkeeper lies a very unconventional history. Carlo was injured in a car crash at the age of fourteen and completely gave up football after that. It was only when he turned 20 that he once more found his way back on the pitch and was picked up by Crystal Palace. After 2 seasons with Palace he went back to the North Weast to play for Stockport County.
Carlo was spotted by City and manager Joe Royle wanted him as cover for the promising, but erratic, Nicky Weaver. It wasn't long before Carlo put himself into the driving seat, and at the end of the 2000-2001 premiership campaign it was Carlo who was first choice between the posts for City.
The following season Carlo and Nicky remained contenders for the number 1 jersey, and with two excellent goalkeepers to choose from Kevin Keegan will not have to worry to much about that position for a while.
After a good spell in the team during the 2001/2002 campaign, Carlo found himself on the side-line when Peter Schmeichel camte to the club in 2002. After making 9 appearances on City's return to the Premiership, Carlo was not satisfied with the situation and so when David Seaman replaced Schmeicel as City's number one Carlo was eager to switch clubs to restart his career..
Middlesbrough came in for the unsettled Goalkeeper just before the opening game in August 2003, to cover the gap left by the departure of goalkeeper Mark Crossley. The 29 year old agreed to move to the Riverside for a nominal fee and competed with Mark Schwarzer for the number one spot.