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Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated: 1 00:00:02,536 --> 00:00:04,436 Narrator: In ireland... 2 00:00:04,438 --> 00:00:06,472 We're 200 feet off the river. 3 00:00:06,474 --> 00:00:08,507 Narrator: ...An elite team of engineers 4 00:00:08,509 --> 00:00:11,343 Is embarking on an epic endeavor. 5 00:00:11,345 --> 00:00:16,582 We're all joined and connected by this desire to build bridges. 6 00:00:16,584 --> 00:00:18,784 Narrator: They're attempting to build the biggest bridge 7 00:00:18,786 --> 00:00:20,719 The country has ever seen. 8 00:00:21,856 --> 00:00:23,822 Man: Slow. Slow! 9 00:00:25,459 --> 00:00:26,892 Narrator: To complete this incredible 10 00:00:26,894 --> 00:00:30,863 Half-mile river crossing in a mere 44 months... 11 00:00:30,865 --> 00:00:33,032 Inching it millimeter by millimeter. 12 00:00:33,034 --> 00:00:36,301 Narrator: ...The team must battle massive loads... 13 00:00:40,441 --> 00:00:43,809 ...Unpredictable weather, and precarious heights. 14 00:00:43,811 --> 00:00:46,078 A project like this comes to you once in a lifetime. 15 00:00:46,080 --> 00:00:48,013 Narrator: This incredible bridge ranks 16 00:00:48,015 --> 00:00:52,251 In a league of ambitious new engineering wonders 17 00:00:52,253 --> 00:00:56,855 That are bigger, faster, taller, and more advanced 18 00:00:56,857 --> 00:00:59,858 Than anything ever constructed before. 19 00:00:59,860 --> 00:01:03,695 This is the inside story of the extraordinary challenge 20 00:01:03,697 --> 00:01:06,765 Of building these giants. 21 00:01:06,767 --> 00:01:09,768 -- Captions by vitac -- www.Vitac.Com 22 00:01:09,770 --> 00:01:12,805 Captions paid for by discovery communications 23 00:01:17,378 --> 00:01:20,212 Southeastern ireland. 24 00:01:20,214 --> 00:01:24,550 Small country roads connect the quaint villages 25 00:01:24,552 --> 00:01:28,954 And farms that dot these green hills. 26 00:01:28,956 --> 00:01:32,257 The landscape is a patchwork of spectacular valleys 27 00:01:32,259 --> 00:01:34,226 And beautiful rivers. 28 00:01:34,228 --> 00:01:37,229 ♪ 29 00:01:37,231 --> 00:01:40,699 One of the largest, the mighty barrow river, 30 00:01:40,701 --> 00:01:44,670 Flows for more than 120 miles to the sea. 31 00:01:44,672 --> 00:01:47,039 The only way across for the residents who live 32 00:01:47,041 --> 00:01:51,076 On either side of this river is the small o'hanrahan bridge 33 00:01:51,078 --> 00:01:55,347 In the center of the harbor town of new ross. 34 00:01:55,349 --> 00:01:57,883 Heavy traffic between the busy city of cork 35 00:01:57,885 --> 00:02:00,185 And the growing town of wexford 36 00:02:00,187 --> 00:02:03,722 Has to pass through this tight bottleneck, 37 00:02:03,724 --> 00:02:07,226 And it's taking its toll on the town. 38 00:02:07,228 --> 00:02:11,263 Now a team of engineers is attempting to divert the road 39 00:02:11,265 --> 00:02:17,236 And build an extraordinary new bridge three miles downriver. 40 00:02:17,238 --> 00:02:21,373 This new divided highway will remove traffic from the town 41 00:02:21,375 --> 00:02:26,111 And soar over the barrow river, conquering its wide waters. 42 00:02:26,113 --> 00:02:28,780 ♪ 43 00:02:28,782 --> 00:02:31,116 Lucia blanco is one of the engineers 44 00:02:31,118 --> 00:02:33,719 Designing this record-breaking megabridge. 45 00:02:52,106 --> 00:02:55,274 This cutting-edge crossing will stretch more than 1/2 mile 46 00:02:55,276 --> 00:02:58,777 Over the river to become the longest bridge in ireland. 47 00:02:58,779 --> 00:03:01,480 ♪ 48 00:03:01,482 --> 00:03:05,117 The rose fitzgerald kennedy bridge 49 00:03:05,119 --> 00:03:09,855 Will stretch more than 1/2 mile across the valley. 50 00:03:09,857 --> 00:03:11,290 In the middle of the river, 51 00:03:11,292 --> 00:03:15,260 An enormous tower rises out of the water, 52 00:03:15,262 --> 00:03:19,831 Soaring nearly 200 feet into the sky. 53 00:03:19,833 --> 00:03:25,237 The towers support 34 bundles of steel cables 54 00:03:25,239 --> 00:03:28,507 That hold up the enormous concrete roadway 55 00:03:28,509 --> 00:03:32,511 More than 3,000 feet from one side to the other. 56 00:03:32,513 --> 00:03:35,013 ♪ 57 00:03:35,015 --> 00:03:36,848 This record-breaking bridge 58 00:03:36,850 --> 00:03:39,384 Will not only be the longest bridge in ireland 59 00:03:39,386 --> 00:03:43,322 But the longest bridge of its type in the entire world. 60 00:03:43,324 --> 00:03:48,293 ♪ 61 00:03:48,295 --> 00:03:50,329 Building this bridge won't be easy. 62 00:03:50,331 --> 00:03:52,431 ♪ 63 00:03:52,433 --> 00:03:55,367 The new bridge needs to be both very long 64 00:03:55,369 --> 00:03:58,136 To span the huge width of the waterway 65 00:03:58,138 --> 00:04:03,709 And very high to allow tall ships to pass underneath. 66 00:04:03,711 --> 00:04:07,145 Building on this scale will be a huge challenge. 67 00:04:26,233 --> 00:04:28,400 This super spanned structure 68 00:04:28,402 --> 00:04:30,869 Will push the limits of bridge engineering. 69 00:04:30,871 --> 00:04:33,639 ♪ 70 00:04:33,641 --> 00:04:35,907 The team will begin on land, 71 00:04:35,909 --> 00:04:40,112 Building 11 concrete towers on either side of the river, 72 00:04:40,114 --> 00:04:42,914 But the base of the massive central tower 73 00:04:42,916 --> 00:04:46,251 Must sit in more than 10 feet of fast-running water. 74 00:04:46,253 --> 00:04:48,453 ♪ 75 00:04:48,455 --> 00:04:51,723 So here, they must build an artificial island... 76 00:04:51,725 --> 00:04:54,226 ♪ 77 00:04:54,228 --> 00:04:57,229 ...Then drive supporting foundation piles 78 00:04:57,231 --> 00:05:01,300 Through the soft riverbed to the bedrock below. 79 00:05:01,302 --> 00:05:03,235 With its foundation in place, 80 00:05:03,237 --> 00:05:06,638 The bridge's enormous central tower rises up. 81 00:05:06,640 --> 00:05:09,007 ♪ 82 00:05:09,009 --> 00:05:12,311 Once the tower is complete, engineers build the roadway 83 00:05:12,313 --> 00:05:16,515 With custom-made mobile concrete molds 84 00:05:16,517 --> 00:05:19,318 And attach steel cables to support the road 85 00:05:19,320 --> 00:05:21,653 As they move along. 86 00:05:21,655 --> 00:05:24,489 Finally, with millimeter accuracy, 87 00:05:24,491 --> 00:05:29,561 They meet in the middle to form one giant solid structure. 88 00:05:29,563 --> 00:05:31,630 At least, that's the plan. 89 00:05:31,632 --> 00:05:34,900 ♪ 90 00:05:34,902 --> 00:05:37,336 In order to access the barrow bridge, 91 00:05:37,338 --> 00:05:39,738 Workers first build a new highway 92 00:05:39,740 --> 00:05:42,941 To route traffic around the town. 93 00:05:42,943 --> 00:05:45,477 Work begins in 2016. 94 00:05:45,479 --> 00:05:46,511 ♪ 95 00:05:52,619 --> 00:05:55,487 Workers plow the new road through the rolling hills 96 00:05:55,489 --> 00:05:59,958 Of the irish countryside down towards both riverbanks, 97 00:05:59,960 --> 00:06:03,028 Where they hit their first major problem, 98 00:06:03,030 --> 00:06:04,663 Building in the river. 99 00:06:09,370 --> 00:06:13,205 To build this colossal crossing, the team will need to construct 100 00:06:13,207 --> 00:06:16,041 A road support in the middle of the river, 101 00:06:16,043 --> 00:06:20,178 A huge central pier rising out of the water, 102 00:06:20,180 --> 00:06:23,048 But the low tide exposes hundreds of yards 103 00:06:23,050 --> 00:06:25,917 Of very deep, very soft mud. 104 00:06:39,333 --> 00:06:43,535 Engineers cannot build on top of this soft mud, 105 00:06:43,537 --> 00:06:48,673 But the team has a radical solution to the problem. 106 00:06:48,675 --> 00:06:52,310 They will build their own artificial solid ground 107 00:06:52,312 --> 00:06:54,546 Out in the middle of the water. 108 00:06:54,548 --> 00:06:57,449 ♪ 109 00:06:57,451 --> 00:06:59,217 To build the bridge's central tower, 110 00:06:59,219 --> 00:07:02,287 The team must first create a solid base 111 00:07:02,289 --> 00:07:04,856 In the middle of the river, 112 00:07:04,858 --> 00:07:08,160 But if they simply piled rock into the water, 113 00:07:08,162 --> 00:07:11,096 It would sink into the mud and be washed away 114 00:07:11,098 --> 00:07:13,598 By the river's strong tidal currents. 115 00:07:13,600 --> 00:07:15,767 ♪ 116 00:07:15,769 --> 00:07:19,438 Instead, they lay high-tech super strong fabrics 117 00:07:19,440 --> 00:07:22,941 Called geotextiles in the riverbed. 118 00:07:22,943 --> 00:07:26,611 Then they pile the rock, blasted from the riverbanks, 119 00:07:26,613 --> 00:07:28,914 On top. 120 00:07:28,916 --> 00:07:32,217 The geotextile works like a snowshoe, 121 00:07:32,219 --> 00:07:37,355 Evenly distributing the weight of the rock on the unstable mud. 122 00:07:37,357 --> 00:07:40,625 Additional layers on top hold the rock in place, 123 00:07:40,627 --> 00:07:44,729 Preventing it from being washed away. 124 00:07:44,731 --> 00:07:49,501 The end result is a stable artificial island 125 00:07:49,503 --> 00:07:51,603 That will form a solid base 126 00:07:51,605 --> 00:07:55,907 For the bridge's vital central tower. 127 00:07:55,909 --> 00:08:00,512 It takes just three months to construct the artificial island. 128 00:08:00,514 --> 00:08:03,482 This creates a huge square platform 129 00:08:03,484 --> 00:08:08,353 On top of which the team can now build a massive concrete tower. 130 00:08:08,355 --> 00:08:12,557 These act as the bridge's legs, supporting the roadway. 131 00:08:12,559 --> 00:08:14,659 Hey! Hey! Hey! Hey! 132 00:08:14,661 --> 00:08:16,628 Narrator: Once the towers are in position, 133 00:08:16,630 --> 00:08:20,198 The team must gear up to perform an aerial balancing act 134 00:08:20,200 --> 00:08:22,968 And construct the record-breaking roadway 135 00:08:22,970 --> 00:08:26,872 147 feet above the mighty river. 136 00:08:26,874 --> 00:08:28,673 ♪ 137 00:08:28,675 --> 00:08:30,375 Ah [bleep] they're stuck like -- look. 138 00:08:30,377 --> 00:08:33,979 ♪ 139 00:08:40,754 --> 00:08:43,555 ♪ 140 00:08:43,557 --> 00:08:45,690 Narrator: In southeastern ireland, 141 00:08:45,692 --> 00:08:47,392 An elite construction team 142 00:08:47,394 --> 00:08:50,462 Is attempting to build a record-breaking megabridge 143 00:08:50,464 --> 00:08:54,199 Across one of the country's biggest rivers. 144 00:08:54,201 --> 00:08:56,368 After 23 months of work, 145 00:08:56,370 --> 00:09:00,772 The bridge's central support pillar is in place. 146 00:09:00,774 --> 00:09:04,142 Now the team is ready to begin the next phase, 147 00:09:04,144 --> 00:09:06,111 Building the road deck, 148 00:09:06,113 --> 00:09:10,782 But they'll have to do this part of the job in midair. 149 00:09:10,784 --> 00:09:12,651 Mark whelan is part of the team 150 00:09:12,653 --> 00:09:15,687 Responsible for extending the bridge over the river. 151 00:09:25,132 --> 00:09:28,667 Ironworkers, carpenters, surveyors, and laborers 152 00:09:28,669 --> 00:09:33,204 All work together in the shadow of a massive steel frame 153 00:09:33,206 --> 00:09:38,343 Called the form traveler, a vast concrete mold 154 00:09:38,345 --> 00:09:43,014 That shapes each new section of the road deck. 155 00:09:43,016 --> 00:09:45,684 This is how it works. 156 00:09:45,686 --> 00:09:49,187 First, the traveler's powerful hydraulics 157 00:09:49,189 --> 00:09:54,492 Shift the whole mold forwards into thin air. 158 00:09:54,494 --> 00:10:00,131 It now extends more than 20 feet beyond the edge of the bridge. 159 00:10:00,133 --> 00:10:04,302 Underneath, enormous steel struts connect it to the tower, 160 00:10:04,304 --> 00:10:06,471 Supporting its massive weight. 161 00:10:06,473 --> 00:10:08,306 ♪ 162 00:10:08,308 --> 00:10:09,874 When it's in position, 163 00:10:09,876 --> 00:10:12,477 Workers fill the mold with concrete. 164 00:10:12,479 --> 00:10:15,313 ♪ 165 00:10:15,315 --> 00:10:17,082 Once the concrete is set, 166 00:10:17,084 --> 00:10:20,485 The traveler moves forward again, 167 00:10:20,487 --> 00:10:25,590 Supported by the super strong concrete section it just molded. 168 00:10:25,592 --> 00:10:28,627 Four travelers move outward simultaneously 169 00:10:28,629 --> 00:10:31,730 From each side of the two huge spans 170 00:10:31,732 --> 00:10:33,598 And will eventually meet in the middle 171 00:10:33,600 --> 00:10:35,600 To complete the road deck. 172 00:10:35,602 --> 00:10:39,971 ♪ 173 00:10:39,973 --> 00:10:42,807 The team gears up to move the central traveler 174 00:10:42,809 --> 00:10:46,344 Out over the river, but it won't be easy. 175 00:10:46,346 --> 00:10:49,414 They have to move it uphill. 176 00:10:58,358 --> 00:11:00,792 It takes two teams working in tandem 177 00:11:00,794 --> 00:11:06,364 To move the traveler uphill, one above deck and one below. 178 00:11:06,366 --> 00:11:09,000 Mark is getting in position below deck. 179 00:11:18,545 --> 00:11:20,578 With everybody in position, 180 00:11:20,580 --> 00:11:23,481 The team starts the hydraulic arms. 181 00:11:23,483 --> 00:11:28,420 The pistons push the 200-ton steel frame 2 feet at a time, 182 00:11:28,422 --> 00:11:32,624 Inching it closer and closer to the edge. 183 00:11:32,626 --> 00:11:35,860 At the same time, the team below uses brute force 184 00:11:35,862 --> 00:11:38,430 To winch the form traveler forwards. 185 00:11:38,432 --> 00:11:39,898 We're going uphill. 186 00:11:39,900 --> 00:11:42,033 We're more steep now than we initially were back there. 187 00:11:42,035 --> 00:11:44,369 So we're creeping up the hill now, 188 00:11:44,371 --> 00:11:47,605 So there's more load on the back of the traveler. 189 00:11:47,607 --> 00:11:50,375 Narrator: The steep incline makes winching out 190 00:11:50,377 --> 00:11:53,845 The underside of the traveler by hand a physical challenge. 191 00:11:53,847 --> 00:11:56,247 ♪ 192 00:11:56,249 --> 00:11:59,084 ♪ row, row, row, row ♪ 193 00:11:59,086 --> 00:12:00,585 ♪ 194 00:12:00,587 --> 00:12:03,421 Narrator: Both teams have to move in perfect unison 195 00:12:03,423 --> 00:12:06,157 To keep the traveler moving straight, 196 00:12:06,159 --> 00:12:09,394 But very quickly, something gets jammed. 197 00:12:10,564 --> 00:12:12,063 Look. 198 00:12:12,065 --> 00:12:14,599 Narrator: The lever becomes almost impossible to move, 199 00:12:14,601 --> 00:12:17,068 And the form traveler comes to a halt. 200 00:12:17,070 --> 00:12:20,105 It's stuck against the bridge itself. 201 00:12:20,107 --> 00:12:22,107 Whelan: At the moment here, this plywood is too tight 202 00:12:22,109 --> 00:12:23,942 Against the existing concrete, 203 00:12:23,944 --> 00:12:27,078 So it's wedging against the traveler. 204 00:12:27,080 --> 00:12:29,114 So basically, what we need to do now 205 00:12:29,116 --> 00:12:32,283 Is let this down about 2 to 3 centimeters, 206 00:12:32,285 --> 00:12:35,019 And then that'll give play so the traveler can slide through. 207 00:12:35,021 --> 00:12:37,455 So at the moment, it's wedged. 208 00:12:37,457 --> 00:12:40,925 Narrator: The team races to loosen the supporting steel bars 209 00:12:40,927 --> 00:12:45,230 And lower the form traveler away from the concrete bridge deck. 210 00:12:45,232 --> 00:12:46,865 With the supporting bars loosened 211 00:12:46,867 --> 00:12:49,400 And the traveler free from the concrete, 212 00:12:49,402 --> 00:12:50,969 They try again. 213 00:12:50,971 --> 00:12:53,538 Inching it millimeter by millimeter. 214 00:12:53,540 --> 00:12:55,406 Narrator: But tension is rising 215 00:12:55,408 --> 00:12:57,942 In both the traveler and the team. 216 00:12:57,944 --> 00:13:00,245 Very hard work, today it is. 217 00:13:00,247 --> 00:13:02,580 It's not normally like this. 218 00:13:02,582 --> 00:13:05,650 Narrator: The team tries to haul the traveler further uphill. 219 00:13:05,652 --> 00:13:09,220 Ah [bleep] they're stuck like -- look. 220 00:13:09,222 --> 00:13:12,257 Narrator: But it gets stuck again. 221 00:13:12,259 --> 00:13:14,859 With so many intricate moving parts, 222 00:13:14,861 --> 00:13:18,263 It takes a while to identify the problem. 223 00:13:18,265 --> 00:13:20,865 The shackle got caught in front of the beam, 224 00:13:20,867 --> 00:13:22,267 So we couldn't move it forward. 225 00:13:22,269 --> 00:13:23,735 So everything is good to go now. 226 00:13:23,737 --> 00:13:25,703 So you guys moving really easy right now? 227 00:13:25,705 --> 00:13:30,341 After an hour of fine-tuning, the form traveler finally comes 228 00:13:30,343 --> 00:13:32,877 To a stop in the perfect position. 229 00:13:32,879 --> 00:13:34,145 Whelan: We're finished now. 230 00:13:34,147 --> 00:13:37,949 We got the beam in the correct location. 231 00:13:37,951 --> 00:13:39,684 Narrator: Now mark and his team 232 00:13:39,686 --> 00:13:43,755 Have to fill the traveling form work with concrete. 233 00:13:43,757 --> 00:13:48,793 They must pump the concrete more than 150 feet up from the ground 234 00:13:48,795 --> 00:13:53,031 And more than 100 feet to the end of the bridge. 235 00:13:53,033 --> 00:13:55,033 It's no easy task. 236 00:13:55,035 --> 00:13:57,068 ♪ 237 00:14:05,478 --> 00:14:09,347 The team must lay the concrete from the inside out, 238 00:14:09,349 --> 00:14:13,051 Ducking under low ceilings and squeezing into tight areas 239 00:14:13,053 --> 00:14:16,187 In the dark interior of the bridge. 240 00:14:16,189 --> 00:14:18,723 They need to fill the walls and base of the traveler 241 00:14:18,725 --> 00:14:22,493 With concrete first to support the road deck. 242 00:14:28,301 --> 00:14:31,302 They must spread it with millimeter precision... 243 00:14:32,405 --> 00:14:35,540 ...Or the bridge could end up off-balance. 244 00:14:40,013 --> 00:14:42,714 ♪ 245 00:14:49,456 --> 00:14:53,057 ♪ 246 00:14:53,059 --> 00:14:54,993 Narrator: In southeastern ireland, 247 00:14:54,995 --> 00:14:57,262 An international team of engineers 248 00:14:57,264 --> 00:14:59,597 Is extending the concrete road deck 249 00:14:59,599 --> 00:15:03,635 Of ireland's newest and longest bridge. 250 00:15:03,637 --> 00:15:05,637 They must spread the fresh concrete 251 00:15:05,639 --> 00:15:09,207 With millimeter precision. 252 00:15:09,209 --> 00:15:11,042 If the concrete is uneven, 253 00:15:11,044 --> 00:15:14,612 Not only could it create a bumpy ride for any vehicles, 254 00:15:14,614 --> 00:15:17,348 But it could also lead to structural imbalances 255 00:15:17,350 --> 00:15:20,285 In the bridge itself. 256 00:15:20,287 --> 00:15:24,322 It takes more than 8 hours to lay this new 20-foot section 257 00:15:24,324 --> 00:15:26,424 Of road deck. 258 00:15:26,426 --> 00:15:31,596 The team finishes the pour just as the concrete starts to set. 259 00:15:31,598 --> 00:15:32,630 Whelan: Yeah. 260 00:15:32,632 --> 00:15:33,631 No problems, everything went well. 261 00:15:33,633 --> 00:15:34,866 Everything went smooth. 262 00:15:34,868 --> 00:15:36,100 I think it's the quickest one we've done yet. 263 00:15:36,102 --> 00:15:39,404 We started pumping concrete about 6:15 a.M. 264 00:15:39,406 --> 00:15:41,472 I think it's now 2:30. 265 00:15:41,474 --> 00:15:44,509 Narrator: The sheer scale of this megastructure requires 266 00:15:44,511 --> 00:15:48,513 More than 32,000 cubic yards of concrete, 267 00:15:48,515 --> 00:15:51,182 And the unusual design of the bridge 268 00:15:51,184 --> 00:15:55,386 Calls for a particularly strong mix. 269 00:15:55,388 --> 00:15:58,823 Concrete dries quickly, so the bridge's engineers 270 00:15:58,825 --> 00:16:03,461 Need to source all of the fresh wet concrete locally. 271 00:16:03,463 --> 00:16:06,431 It's made here at the kilmacow concrete plant 272 00:16:06,433 --> 00:16:09,200 Only 12 miles away. 273 00:16:09,202 --> 00:16:11,703 95 newton is a particularly strong concrete. 274 00:16:11,705 --> 00:16:13,237 The strengths of this ilk, 275 00:16:13,239 --> 00:16:15,340 They don't come around very often. 276 00:16:15,342 --> 00:16:18,409 Narrator: Expert concrete technician colin heffernan 277 00:16:18,411 --> 00:16:22,380 Is responsible for ensuring the mix is perfect. 278 00:16:22,382 --> 00:16:25,416 We combine different aggregates, which are cements, 279 00:16:25,418 --> 00:16:26,584 Your admixtures, and your waters. 280 00:16:26,586 --> 00:16:29,287 What you've got here is a 10 millstone, 281 00:16:29,289 --> 00:16:35,526 So you combine that with sand, part of your fine aggregate, 282 00:16:35,528 --> 00:16:39,864 And then also a coarser chip again, 14 millstone. 283 00:16:39,866 --> 00:16:42,567 All of these different aggregates are combined together 284 00:16:42,569 --> 00:16:45,203 To give you that cohesive mix 285 00:16:45,205 --> 00:16:50,908 That will produce the strength required for the bridge. 286 00:16:50,910 --> 00:16:53,745 Narrator: Enormous loading bins release the required amount 287 00:16:53,747 --> 00:16:57,615 Of each aggregate onto a conveyor belt below. 288 00:16:57,617 --> 00:16:58,750 The door opens. 289 00:16:58,752 --> 00:17:00,752 The aggregate drops onto the weigh conveyor, 290 00:17:00,754 --> 00:17:05,289 And that weighs the proportion of that aggregate in the mix. 291 00:17:05,291 --> 00:17:08,292 Narrator: The conveyor belt itself weighs each ingredient 292 00:17:08,294 --> 00:17:10,628 To ensure the mixture is perfect, 293 00:17:10,630 --> 00:17:13,398 Then transports it to the mixer. 294 00:17:13,400 --> 00:17:15,299 But the aggregates will now be transferred up 295 00:17:15,301 --> 00:17:16,701 To a central mixer, 296 00:17:16,703 --> 00:17:18,669 And there, they'll be mixed with the cements, 297 00:17:18,671 --> 00:17:21,005 The water, and the chemical admixtures, 298 00:17:21,007 --> 00:17:24,575 Following which the concrete will be discharged into a truck, 299 00:17:24,577 --> 00:17:25,977 And then we're going to go over to the lab 300 00:17:25,979 --> 00:17:28,946 And we're going to test the actual concrete mix. 301 00:17:28,948 --> 00:17:30,481 Narrator: Colin takes a sample 302 00:17:30,483 --> 00:17:32,850 From every load leaving the site. 303 00:17:32,852 --> 00:17:35,319 He must ensure the concrete is strong enough 304 00:17:35,321 --> 00:17:37,021 To use on the bridge. 305 00:17:39,893 --> 00:17:44,295 In deep storage, he has sample cubes of the concrete mix 306 00:17:44,297 --> 00:17:47,198 That have been curing for 4 weeks. 307 00:17:47,200 --> 00:17:50,768 What we have here are c80/95 cubes. 308 00:17:50,770 --> 00:17:52,904 They were manufactured 28 days ago, 309 00:17:52,906 --> 00:17:55,039 And we're going to crush them today. 310 00:17:55,041 --> 00:17:56,641 Narrator: Before the test, 311 00:17:56,643 --> 00:17:59,043 Colin removes any small imperfections 312 00:17:59,045 --> 00:18:03,681 And makes sure each cube has a consistent weight. 313 00:18:03,683 --> 00:18:05,983 All concrete has a structural limit. 314 00:18:05,985 --> 00:18:09,587 If you apply too much force, it will crack and explode. 315 00:18:09,589 --> 00:18:12,190 This is a compression machine, which is used to assess 316 00:18:12,192 --> 00:18:14,525 The compressive strength of the actual concrete cubes. 317 00:18:14,527 --> 00:18:18,529 We need this cube to meet a target of 95 newtons. 318 00:18:18,531 --> 00:18:20,598 Narrator: Colin starts up the machine, 319 00:18:20,600 --> 00:18:23,801 Which slowly increases the pressure on the cube. 320 00:18:23,803 --> 00:18:26,971 At the moment, you can see that the upper plate 321 00:18:26,973 --> 00:18:30,108 Is compressing on the cube, exerting a force on it. 322 00:18:30,110 --> 00:18:31,542 The force is building. 323 00:18:31,544 --> 00:18:37,381 We'd expect that force to go to 1,050 or 1,100. 324 00:18:37,383 --> 00:18:38,883 Narrator: Every second, 325 00:18:38,885 --> 00:18:41,586 It approaches its target strength. 326 00:18:41,588 --> 00:18:43,721 Eventually, cracks begin to appear 327 00:18:43,723 --> 00:18:47,058 In the side of the cube until... 328 00:18:47,060 --> 00:18:48,659 It explodes. 329 00:18:50,797 --> 00:18:54,632 But colin is happy with the results. 330 00:18:54,634 --> 00:18:58,402 114.2 newtons per millimeter squared -- 331 00:18:58,404 --> 00:19:00,872 It's far exceeded the target strength 332 00:19:00,874 --> 00:19:03,975 And shows that the concrete is suitable for use 333 00:19:03,977 --> 00:19:05,476 In the bridge itself. 334 00:19:05,478 --> 00:19:07,478 Narrator: More than 4,000 trucks 335 00:19:07,480 --> 00:19:09,614 Full of this super strength concrete 336 00:19:09,616 --> 00:19:11,282 Are needed to complete the bridge. 337 00:19:11,284 --> 00:19:16,821 It's thanks to these tests on every batch of concrete 338 00:19:16,823 --> 00:19:19,257 That the build team has ultimate confidence 339 00:19:19,259 --> 00:19:21,259 In the strength of their bridge. 340 00:19:21,261 --> 00:19:26,931 ♪ 341 00:19:26,933 --> 00:19:31,769 On-site, the team is now 39 months into the bridge build. 342 00:19:31,771 --> 00:19:33,971 ♪ 343 00:19:33,973 --> 00:19:37,875 They're making good progress, but as the roadways get longer, 344 00:19:37,877 --> 00:19:40,178 There's a new problem. 345 00:19:40,180 --> 00:19:42,013 They move. 346 00:19:47,787 --> 00:19:51,322 It's marcos sanchez's job to ensure that each new section 347 00:19:51,324 --> 00:19:54,725 Of the bridge is positioned correctly. 348 00:19:54,727 --> 00:19:57,795 Building here is a delicate balancing act. 349 00:19:57,797 --> 00:20:01,232 ♪ 350 00:20:01,234 --> 00:20:03,935 Workers build the road deck out in both directions 351 00:20:03,937 --> 00:20:05,603 From the central pier. 352 00:20:05,605 --> 00:20:08,306 ♪ 353 00:20:08,308 --> 00:20:12,210 Each complete section extends the road by 20 feet 354 00:20:12,212 --> 00:20:15,112 But also adds hundreds of tons of weight. 355 00:20:15,114 --> 00:20:17,481 ♪ 356 00:20:17,483 --> 00:20:21,319 The extra weight of each new section pulls the road down 357 00:20:21,321 --> 00:20:26,958 And lifts the opposite side just like a seesaw. 358 00:20:26,960 --> 00:20:29,927 Too much weight on the wrong side will cause the bridge 359 00:20:29,929 --> 00:20:34,131 To fall out of balance with disastrous consequences. 360 00:20:34,133 --> 00:20:36,467 ♪ 361 00:20:36,469 --> 00:20:40,471 The team has to coordinate work on each side of the deck, 362 00:20:40,473 --> 00:20:42,506 Building at the same speed 363 00:20:42,508 --> 00:20:45,309 So that neither side becomes too heavy. 364 00:20:45,311 --> 00:20:52,083 ♪ 365 00:21:03,296 --> 00:21:06,330 This remote solar-powered monitoring station 366 00:21:06,332 --> 00:21:10,301 Keeps watch over the bridge at all times. 367 00:21:10,303 --> 00:21:14,305 It measures every part of the bridge with millimeter accuracy 368 00:21:14,307 --> 00:21:17,441 24 hours a day. 369 00:21:17,443 --> 00:21:20,177 The equipment discovers that the latest road section 370 00:21:20,179 --> 00:21:23,447 Drags one side of the bridge too low. 371 00:21:27,186 --> 00:21:30,021 Marcos has to ensure the road decks will meet 372 00:21:30,023 --> 00:21:31,656 Precisely in the middle, 373 00:21:31,658 --> 00:21:35,159 Or all their hard work will have been for nothing. 374 00:21:35,161 --> 00:21:38,462 ♪ 375 00:21:45,171 --> 00:21:48,306 ♪ 376 00:21:48,308 --> 00:21:51,309 Narrator: In ireland, an elite construction team 377 00:21:51,311 --> 00:21:54,445 Is attempting to build the country's biggest bridge. 378 00:21:54,447 --> 00:21:57,448 They're building two road decks out towards each other 379 00:21:57,450 --> 00:22:00,818 In midair, but one side of the central deck 380 00:22:00,820 --> 00:22:03,154 Is 2 feet lower than it should be. 381 00:22:11,331 --> 00:22:14,799 Bridge designer marcos has a solution. 382 00:22:14,801 --> 00:22:18,336 He uses a complex computer program to predict 383 00:22:18,338 --> 00:22:22,673 How the bridge will react and move as they build each section. 384 00:22:22,675 --> 00:22:25,676 He can then use the support cables to raise each section 385 00:22:25,678 --> 00:22:28,145 Of the bridge back to where it should be. 386 00:22:34,721 --> 00:22:38,823 Marcos is confident he can get the bridge back on track. 387 00:22:44,163 --> 00:22:46,964 As the roadway grows longer and longer, 388 00:22:46,966 --> 00:22:49,667 It needs even more support from above. 389 00:22:49,669 --> 00:22:53,304 ♪ 390 00:22:53,306 --> 00:22:56,707 Specialized engineers must install more than 300 miles 391 00:22:56,709 --> 00:22:58,909 Of solid steel cables 392 00:22:58,911 --> 00:23:01,178 To hold up the ends of the road deck. 393 00:23:01,180 --> 00:23:03,514 ♪ 394 00:23:03,516 --> 00:23:07,284 Today, the team is attempting to install the longest, 395 00:23:07,286 --> 00:23:10,421 Heaviest, and highest cables yet. 396 00:23:10,423 --> 00:23:13,891 ♪ 397 00:23:13,893 --> 00:23:17,061 Thick bundles of steel cables link the road deck 398 00:23:17,063 --> 00:23:20,030 To the bridge's central tower. 399 00:23:20,032 --> 00:23:22,733 To build the cables, engineers first lift 400 00:23:22,735 --> 00:23:25,035 A tough outer casing into position. 401 00:23:25,037 --> 00:23:27,037 ♪ 402 00:23:27,039 --> 00:23:31,509 Next, they individually thread hundreds of super strong cables 403 00:23:31,511 --> 00:23:33,411 Through the casing. 404 00:23:33,413 --> 00:23:35,413 Each cable passes through 405 00:23:35,415 --> 00:23:38,416 A specially constructed steel saddle 406 00:23:38,418 --> 00:23:40,484 And out the other side. 407 00:23:40,486 --> 00:23:44,422 Engineers attach each cable to the underside of the road deck, 408 00:23:44,424 --> 00:23:48,159 Then tension them from both sides at once, 409 00:23:48,161 --> 00:23:51,462 Pulling them tighter and tighter. 410 00:23:51,464 --> 00:23:55,433 Once fully tensioned, the cables form a rigid triangle 411 00:23:55,435 --> 00:24:00,438 Which pulls the road deck inwards and supports its weight. 412 00:24:00,440 --> 00:24:03,474 Workers need to install 34 of these cables 413 00:24:03,476 --> 00:24:09,280 Across the whole bridge to lock the road deck into a solid block 414 00:24:09,282 --> 00:24:13,317 Capable of reaching out across the enormous span. 415 00:24:13,319 --> 00:24:16,387 ♪ 416 00:24:25,731 --> 00:24:26,730 Hey! 417 00:24:26,732 --> 00:24:28,299 Narrator: It's craig sneddon's job 418 00:24:28,301 --> 00:24:31,302 To install the cables that hold the bridge up, 419 00:24:31,304 --> 00:24:34,872 But first, he needs to build a vital plastic casing 420 00:24:34,874 --> 00:24:36,674 To protect the cables. 421 00:24:45,818 --> 00:24:50,554 Craig must construct a pipe nearly 450 feet in length 422 00:24:50,556 --> 00:24:53,724 To hold the longest cables on the bridge so far. 423 00:24:58,164 --> 00:25:00,364 He has to ensure every section 424 00:25:00,366 --> 00:25:03,467 Is joined perfectly with no weak spots, 425 00:25:03,469 --> 00:25:06,170 Or the super long flexible casing 426 00:25:06,172 --> 00:25:08,305 Could bend too far and snap. 427 00:25:20,052 --> 00:25:22,720 Craig's team must shave the pipe sections 428 00:25:22,722 --> 00:25:24,688 Until they're perfectly flat 429 00:25:24,690 --> 00:25:28,826 And will join together with no space or gaps. 430 00:25:28,828 --> 00:25:32,062 A special vice lines up each pipe section 431 00:25:32,064 --> 00:25:36,967 And peels off thin layers until they join together seamlessly, 432 00:25:36,969 --> 00:25:39,036 But to stick them together permanently, 433 00:25:39,038 --> 00:25:41,605 Craig needs to melt them. 434 00:25:51,183 --> 00:25:53,651 After joining 12 sections together, 435 00:25:53,653 --> 00:25:56,954 The pipe is ready for craig to lift it into position. 436 00:26:01,193 --> 00:26:03,994 The team connects the end of the pipe to a crane, 437 00:26:03,996 --> 00:26:06,697 Which needs to lift the heavy, flexible tube 438 00:26:06,699 --> 00:26:08,766 To the top of the tower. 439 00:26:08,768 --> 00:26:12,102 Keep it forward! 440 00:26:12,104 --> 00:26:14,805 Narrator: With the crane securely attached, 441 00:26:14,807 --> 00:26:18,342 The pipe lifts off the ground. 442 00:26:22,915 --> 00:26:25,449 The team has to ensure that the delicate pipe 443 00:26:25,451 --> 00:26:27,585 Doesn't hit anything on the way up. 444 00:26:31,457 --> 00:26:34,091 As the new pipe is lifted clear of the others, 445 00:26:34,093 --> 00:26:37,861 The flexible plastic begins to bend, which is a problem. 446 00:26:49,141 --> 00:26:52,109 Craig and his team needs to straighten the pipe 447 00:26:52,111 --> 00:26:55,913 So the steel cables can slide through without snagging. 448 00:26:55,915 --> 00:26:59,249 They do this with a guide strand... 449 00:27:03,389 --> 00:27:08,058 ...A single steel cable running the length of the pipe. 450 00:27:08,060 --> 00:27:10,361 As craig tightens the guide strand, 451 00:27:10,363 --> 00:27:14,064 It lifts the pipe even further and straightens it out. 452 00:27:29,482 --> 00:27:32,583 In no time at all, the pipe is in position, 453 00:27:32,585 --> 00:27:35,753 But the team isn't finished yet. 454 00:27:35,755 --> 00:27:39,490 They must run 125 steel cables through the middle 455 00:27:39,492 --> 00:27:42,059 So that it can hold up the bridge. 456 00:27:42,061 --> 00:27:45,629 The cables are delivered on huge 3-ton coils. 457 00:27:45,631 --> 00:27:48,832 Each coil holds more than a mile of steel. 458 00:27:57,109 --> 00:28:01,178 They load each steel cable into a cable-pushing machine. 459 00:28:01,180 --> 00:28:03,747 This thrusts the cables at a constant rate 460 00:28:03,749 --> 00:28:07,418 Up the whole length of the pipe through the saddle at the top 461 00:28:07,420 --> 00:28:11,622 And far down to the other side of the bridge. 462 00:28:11,624 --> 00:28:13,757 Once the cable pusher starts, 463 00:28:13,759 --> 00:28:16,760 Craig has to pay close attention to the coil. 464 00:28:22,301 --> 00:28:23,801 ♪ 465 00:28:23,803 --> 00:28:25,569 The team on the ground pushes a cable up 466 00:28:25,571 --> 00:28:27,004 To the top of the tower... 467 00:28:27,006 --> 00:28:29,206 Stop. Stop. 468 00:28:29,208 --> 00:28:31,208 Narrator: ...Where a worker must quickly catch it 469 00:28:31,210 --> 00:28:35,045 And put it through the correct hole in the saddle. 470 00:28:35,047 --> 00:28:38,916 The cable eventually reaches the far side, where it is caught 471 00:28:38,918 --> 00:28:41,785 And fed through the same hole in another block. 472 00:28:45,124 --> 00:28:47,458 Far below the road deck, 473 00:28:47,460 --> 00:28:51,929 Another team works inside the bridge to tension the tables. 474 00:28:51,931 --> 00:28:54,465 With the cables being fed through one by one, 475 00:28:54,467 --> 00:28:57,935 The team inside the bridge have to tighten all of them... 476 00:28:57,937 --> 00:29:00,437 We've got to be strong and physical to do this job. 477 00:29:00,439 --> 00:29:03,774 Narrator: ...Until they take the full weight of the concrete. 478 00:29:03,776 --> 00:29:07,277 ♪ 479 00:29:14,086 --> 00:29:17,755 ♪ 480 00:29:17,757 --> 00:29:20,824 Narrator: In southeastern ireland, 481 00:29:20,826 --> 00:29:24,361 This fearless construction crew is balancing on the edge 482 00:29:24,363 --> 00:29:30,134 Of ireland's largest bridge 150 feet above the barrow river, 483 00:29:30,136 --> 00:29:32,703 But hidden inside the concrete road deck, 484 00:29:32,705 --> 00:29:35,706 A specialized team is working hard to attach 485 00:29:35,708 --> 00:29:40,077 The enormous steel cables that keep the road in place. 486 00:29:40,079 --> 00:29:42,546 These cables, this is what's holding up the structure 487 00:29:42,548 --> 00:29:44,681 Of the bridge, pretty much. 488 00:29:44,683 --> 00:29:48,218 Narrator: It's david o'hara's job to ensure the steel cables 489 00:29:48,220 --> 00:29:51,955 Are tight enough to hold up the bridge. 490 00:29:51,957 --> 00:29:54,024 These thick cables up on the bridge there, 491 00:29:54,026 --> 00:29:55,659 They affect the position. 492 00:29:55,661 --> 00:29:59,530 My job is to go inside and stretch these cables. 493 00:29:59,532 --> 00:30:01,865 Narrator: David has to venture deep inside 494 00:30:01,867 --> 00:30:03,133 The belly of the bridge 495 00:30:03,135 --> 00:30:06,770 To find the ends of the steel strands. 496 00:30:06,772 --> 00:30:10,541 Today, he must secure the longest cable so far, 497 00:30:10,543 --> 00:30:14,812 Which poses a huge challenge. 498 00:30:14,814 --> 00:30:17,214 Well, at the moment, we're inside the bridge, okay? 499 00:30:17,216 --> 00:30:19,616 That's pretty much where all the work has happened. 500 00:30:19,618 --> 00:30:22,719 Everybody tends to think that that's just a road 501 00:30:22,721 --> 00:30:24,521 That you drive over, but no. 502 00:30:24,523 --> 00:30:27,658 Really, this is where all the action happens. 503 00:30:27,660 --> 00:30:30,160 Narrator: Workers on the bridge deck above 504 00:30:30,162 --> 00:30:32,696 Feed the cable strands through a metal tube 505 00:30:32,698 --> 00:30:35,232 Down into the team inside the bridge. 506 00:30:35,234 --> 00:30:37,234 Okay! 507 00:30:37,236 --> 00:30:40,904 This is the anchor block where david will secure each strand 508 00:30:40,906 --> 00:30:43,140 And pull it tight. 509 00:30:43,142 --> 00:30:44,541 Right. Let's get it strapped down, 510 00:30:44,543 --> 00:30:47,811 Pulling through just now and feeding through 511 00:30:47,813 --> 00:30:51,515 For the cable that we're going to install at the moment. 512 00:30:51,517 --> 00:30:54,551 As you can see, it's not simple, 513 00:30:54,553 --> 00:30:56,553 But it is possible. 514 00:30:56,555 --> 00:30:59,957 Yep, keep going! 515 00:30:59,959 --> 00:31:02,593 Workers feed the cables down into the road deck 516 00:31:02,595 --> 00:31:04,928 In a precise order 517 00:31:04,930 --> 00:31:07,297 So david's team inside the bridge 518 00:31:07,299 --> 00:31:10,300 Knows where the next cable will appear. 519 00:31:10,302 --> 00:31:12,269 Well, it is pretty much like threading a needle 520 00:31:12,271 --> 00:31:13,770 Because you put this up there. 521 00:31:13,772 --> 00:31:16,106 You put the gauge strand up the designated hole, 522 00:31:16,108 --> 00:31:18,575 And each hole has got a number. 523 00:31:18,577 --> 00:31:21,879 Narrator: David uses a hydraulic jack to tighten each cable 524 00:31:21,881 --> 00:31:23,480 As it comes through the anchor. 525 00:31:23,482 --> 00:31:26,917 It almost looks like a bazooka. 526 00:31:26,919 --> 00:31:29,620 Narrator: He puts the jack over the top of each cable 527 00:31:29,622 --> 00:31:31,588 Right up to the anchor. 528 00:31:31,590 --> 00:31:34,925 The jack then pulls the cable through inch by inch, 529 00:31:34,927 --> 00:31:37,160 Locking it in place. 530 00:31:37,162 --> 00:31:40,430 This here is your jack, right, and this is what's pulling 531 00:31:40,432 --> 00:31:42,900 The force of these strands here, yeah? 532 00:31:42,902 --> 00:31:47,004 Narrator: But they have to be precise or a cable could snap. 533 00:31:47,006 --> 00:31:48,906 It's basically like an elastic band. 534 00:31:48,908 --> 00:31:50,274 You're pulling, pulling, pulling, 535 00:31:50,276 --> 00:31:52,276 And if you put too much force, it will pop, 536 00:31:52,278 --> 00:31:55,279 So you only do it a certain percentage. 537 00:31:55,281 --> 00:31:57,281 Narrator: It only takes david a few minutes 538 00:31:57,283 --> 00:32:05,155 To fully stress each strand, but he has to do this 125 times. 539 00:32:05,157 --> 00:32:08,692 With the new cable secure, 540 00:32:08,694 --> 00:32:12,829 The team is able to build out even further over the water. 541 00:32:12,831 --> 00:32:14,831 ♪ 542 00:32:14,833 --> 00:32:18,302 It takes 41 months, but eventually, 543 00:32:18,304 --> 00:32:21,405 The roads approach each other in the middle. 544 00:32:21,407 --> 00:32:24,841 And this is where the final challenge begins. 545 00:32:24,843 --> 00:32:26,510 Harvey, drop it down a bit. 546 00:32:26,512 --> 00:32:28,412 We'll be better with -- drop it down a bit there. 547 00:32:28,414 --> 00:32:30,948 Every moment now is a big moment. 548 00:32:30,950 --> 00:32:33,517 Narrator: It's up to declan roche and his team 549 00:32:33,519 --> 00:32:36,553 To finally join the two ends of the bridge together. 550 00:32:36,555 --> 00:32:38,622 Today is a very big day for us here on the project, 551 00:32:38,624 --> 00:32:42,092 And today is the day when we bring the locking beams, 552 00:32:42,094 --> 00:32:46,863 Which are going to fix the two bridge decks together to size. 553 00:32:46,865 --> 00:32:49,166 We're going to install them. 554 00:32:49,168 --> 00:32:51,802 Narrator: After more than three years of building, 555 00:32:51,804 --> 00:32:54,304 The road decks are almost touching, 556 00:32:54,306 --> 00:32:57,107 But they've run into a problem. 557 00:32:57,109 --> 00:32:59,343 You see the central point is beyond the traveler bars, 558 00:32:59,345 --> 00:33:00,978 So that won't work. 559 00:33:00,980 --> 00:33:04,147 One road is lower than the other. 560 00:33:04,149 --> 00:33:06,683 We clearly cannot have a step or a speed ramp 561 00:33:06,685 --> 00:33:07,851 In the middle of the bridge. 562 00:33:07,853 --> 00:33:09,419 That wouldn't work at all, so no, 563 00:33:09,421 --> 00:33:11,421 It is very important that we bring these together. 564 00:33:11,423 --> 00:33:13,223 Narrator: The team has to ensure 565 00:33:13,225 --> 00:33:15,726 The roads are the exact same height, 566 00:33:15,728 --> 00:33:19,463 And they have a genius plan to bring each side together. 567 00:33:19,465 --> 00:33:20,764 Roche: We've had a lot of people wondering 568 00:33:20,766 --> 00:33:23,266 How are we going to bring the bridge decks together? 569 00:33:23,268 --> 00:33:25,235 ♪ 570 00:33:25,237 --> 00:33:27,304 Narrator: With the bridge nearing completion, 571 00:33:27,306 --> 00:33:30,407 One side of the roadway is nearly 2 feet higher 572 00:33:30,409 --> 00:33:32,175 Than the other. 573 00:33:32,177 --> 00:33:35,746 To bridge this gap, first, engineers securely 574 00:33:35,748 --> 00:33:40,183 Attach colossal steel beams to the higher side. 575 00:33:40,185 --> 00:33:43,420 Next, they use long bolts to connect the beams 576 00:33:43,422 --> 00:33:45,989 To the lower side of the bridge. 577 00:33:45,991 --> 00:33:49,726 Then small but mighty hydraulic jacks 578 00:33:49,728 --> 00:33:55,098 Will slowly pull the lower road deck up to meet the steel beams, 579 00:33:55,100 --> 00:33:59,669 Raising the whole concrete deck to the same level. 580 00:33:59,671 --> 00:34:04,041 Finally, they move the remaining traveler out across the gap, 581 00:34:04,043 --> 00:34:10,480 Connecting it to the other side for one last concrete cast. 582 00:34:10,482 --> 00:34:16,420 Once they finish both gaps, the bridge will be complete. 583 00:34:16,422 --> 00:34:19,056 Roche: I think the first thing I thought of is, 584 00:34:19,058 --> 00:34:22,292 "that's a really simple, clever idea," 585 00:34:22,294 --> 00:34:25,262 You know, because the best ideas sometimes are the simplest. 586 00:34:25,264 --> 00:34:28,131 Narrator: The first job is to put the locking beams 587 00:34:28,133 --> 00:34:30,300 In the correct position. 588 00:34:30,302 --> 00:34:34,337 The super strong steel beams are more than 36 feet long 589 00:34:34,339 --> 00:34:38,041 And weigh more than 13 tons each. 590 00:34:38,043 --> 00:34:42,145 The team has brought in this special crane to lift them. 591 00:34:42,147 --> 00:34:46,183 The beam itself, as you can see, the beam is quite big. 592 00:34:46,185 --> 00:34:49,686 It's over 1.2 meters in height. 593 00:34:49,688 --> 00:34:51,822 Narrator: There's just one problem. 594 00:34:51,824 --> 00:34:53,857 To lift the enormous locking beams, 595 00:34:53,859 --> 00:34:57,928 The crane needs to extend long stabilizing legs, 596 00:34:57,930 --> 00:35:00,263 But there's not enough room. 597 00:35:00,265 --> 00:35:01,698 We're up in the deck of the bridge, 598 00:35:01,700 --> 00:35:04,668 And space is very constrained. 599 00:35:04,670 --> 00:35:07,037 The bridge itself is relatively narrow. 600 00:35:07,039 --> 00:35:10,607 It's four lanes in total, two lanes on either side, 601 00:35:10,609 --> 00:35:13,276 But because we've got the cables here in the middle, 602 00:35:13,278 --> 00:35:16,480 It restricts the space we have for the crane. 603 00:35:16,482 --> 00:35:19,549 The team scrambles to move heavy equipment and machinery 604 00:35:19,551 --> 00:35:23,453 Around the deck to clear a path for the crane. 605 00:35:23,455 --> 00:35:25,122 Yeah. It should be okay. 606 00:35:25,124 --> 00:35:27,357 3 meters to the middle of the pad. 607 00:35:27,359 --> 00:35:31,027 It was a meter back, but here, it should be okay. 608 00:35:31,029 --> 00:35:34,798 It should have this much to spare. 609 00:35:34,800 --> 00:35:37,868 Narrator: It's a tight squeeze, but the crew has cleared 610 00:35:37,870 --> 00:35:41,605 Just enough space to extend and stabilize the crane. 611 00:35:41,607 --> 00:35:43,106 It's the middle part. 612 00:35:43,108 --> 00:35:44,908 Okay. 613 00:35:44,910 --> 00:35:47,110 With the crane finally in position, 614 00:35:47,112 --> 00:35:50,480 They're ready to lift the locking beams into place. 615 00:35:50,482 --> 00:35:52,716 Roche: We have to be very precise on how we place these. 616 00:35:52,718 --> 00:35:55,118 The holes in the deck and the holes in the beam, 617 00:35:55,120 --> 00:35:57,254 They got to line up really precisely. 618 00:35:57,256 --> 00:35:59,789 There's not a lot of room for error. 619 00:35:59,791 --> 00:36:02,859 Narrator: Workers on either side of the divide use ropes 620 00:36:02,861 --> 00:36:06,263 To guide the beam and gently lower it over the span. 621 00:36:06,265 --> 00:36:07,330 All right. Let's go! 622 00:36:07,332 --> 00:36:08,665 It's going up this way. 623 00:36:08,667 --> 00:36:09,933 Evan! 624 00:36:09,935 --> 00:36:12,936 I'm going to pull her around a bit now, yeah? 625 00:36:12,938 --> 00:36:14,271 Harvey, drop it down a bit. 626 00:36:14,273 --> 00:36:16,940 We'll be better with -- drop it down a bit there. 627 00:36:16,942 --> 00:36:20,210 Narrator: They drop the locking beams onto special bases 628 00:36:20,212 --> 00:36:22,846 And carefully line up the holes. 629 00:36:22,848 --> 00:36:24,781 As with any of these operations, 630 00:36:24,783 --> 00:36:26,283 There's always a little adjustment 631 00:36:26,285 --> 00:36:29,586 To get the millimeter accuracy that we need. 632 00:36:29,588 --> 00:36:31,655 Narrator: The holes in the base go right through 633 00:36:31,657 --> 00:36:35,325 To the underside of the road deck. 634 00:36:35,327 --> 00:36:37,594 Declan heads to the other side of the bridge 635 00:36:37,596 --> 00:36:40,230 To inspect the difference in height. 636 00:36:40,232 --> 00:36:42,032 Roche: So we've come over to the other side of the river, 637 00:36:42,034 --> 00:36:43,433 And we're going to have a look here 638 00:36:43,435 --> 00:36:45,134 And see where we've put the beam 639 00:36:45,136 --> 00:36:46,937 In this morning from the other side, 640 00:36:46,939 --> 00:36:48,305 And we can have a look at the gap 641 00:36:48,307 --> 00:36:52,642 That's between the deck on the other side of the beam. 642 00:36:52,644 --> 00:36:55,111 Narrator: The locking beam shows the difference in height 643 00:36:55,113 --> 00:36:57,247 Between the road decks. 644 00:36:57,249 --> 00:37:00,784 One side is almost 2 feet higher than the other. 645 00:37:00,786 --> 00:37:01,952 Can I come around behind you? 646 00:37:01,954 --> 00:37:03,386 Sorry. Thanks very much. 647 00:37:03,388 --> 00:37:06,389 The team will need to push the locking beams to the limit 648 00:37:06,391 --> 00:37:08,325 To bring the roads level. 649 00:37:08,327 --> 00:37:10,527 Wade: They've got very restricted access, 650 00:37:10,529 --> 00:37:12,596 Very intricate maneuvers here. 651 00:37:12,598 --> 00:37:15,966 ♪ 652 00:37:22,808 --> 00:37:26,977 ♪ 653 00:37:26,979 --> 00:37:29,212 Narrator: In southeastern ireland, 654 00:37:29,214 --> 00:37:31,114 An international team of experts 655 00:37:31,116 --> 00:37:35,218 Is about to connect two sides of a record-breaking bridge, 656 00:37:35,220 --> 00:37:38,521 But first, they need to make sure they're the same height. 657 00:37:38,523 --> 00:37:43,393 Well, you can see, we've got a distance of 400 millimeters 658 00:37:43,395 --> 00:37:45,962 Or just under 400 millimeters. 659 00:37:45,964 --> 00:37:49,399 Narrator: The team need to lift the entire central concrete road 660 00:37:49,401 --> 00:37:51,034 More than 1 1/2 feet 661 00:37:51,036 --> 00:37:54,137 In order to bring it level with the other side. 662 00:37:54,139 --> 00:37:57,207 Even though it's concrete and steel, it still flexes, 663 00:37:57,209 --> 00:37:58,475 And it still moves. 664 00:37:58,477 --> 00:38:00,777 It's a very long cantilever over there, 665 00:38:00,779 --> 00:38:05,315 And that is the reason why we need these heavy bridge beams 666 00:38:05,317 --> 00:38:09,319 Because we need to lock the two decks together. 667 00:38:09,321 --> 00:38:11,855 Narrator: The crew will return first thing in the morning 668 00:38:11,857 --> 00:38:14,624 To begin the final colossal lift. 669 00:38:14,626 --> 00:38:20,764 ♪ 670 00:38:20,766 --> 00:38:23,466 The team arrives before sunrise. 671 00:38:23,468 --> 00:38:25,502 ♪ 672 00:38:25,504 --> 00:38:28,104 Engineer mike wade takes over from declan 673 00:38:28,106 --> 00:38:31,074 To inspect the leveling of the road decks. 674 00:38:31,076 --> 00:38:32,509 It's early in the morning, 675 00:38:32,511 --> 00:38:34,711 And it's nice that it's actually in the summer. 676 00:38:34,713 --> 00:38:39,082 These jobs in the winter are not so pleasant. 677 00:38:39,084 --> 00:38:41,951 Narrator: The early start not only gives the team more time 678 00:38:41,953 --> 00:38:43,820 To finish the operation, 679 00:38:43,822 --> 00:38:47,991 But the cool air and mist actually make the job easier. 680 00:38:47,993 --> 00:38:51,127 We're starting at 5:00 this morning 681 00:38:51,129 --> 00:38:55,231 Because the temperature of the deck is cool and constant. 682 00:38:55,233 --> 00:38:57,467 During the day, the deck will warm up. 683 00:38:57,469 --> 00:38:59,969 The cantilever actually deflects further, 684 00:38:59,971 --> 00:39:02,372 And so we're trying to get it locked into position 685 00:39:02,374 --> 00:39:04,808 Before the sun comes up and warms the deck. 686 00:39:04,810 --> 00:39:06,710 ♪ 687 00:39:06,712 --> 00:39:10,547 Narrator: To do this, they will use powerful hydraulic jacks 688 00:39:10,549 --> 00:39:14,517 To lift the lower deck to the correct height. 689 00:39:14,519 --> 00:39:17,053 Here, we're having the jacks delivered to be 690 00:39:17,055 --> 00:39:21,491 Installed onto the threaded bars so that they can be tensioned, 691 00:39:21,493 --> 00:39:23,560 So these guys are just lifting it up. 692 00:39:23,562 --> 00:39:27,030 And then they'll lift it over the top of the bar. 693 00:39:27,032 --> 00:39:30,934 Narrator: The hydraulic jacks are too heavy to move by hand, 694 00:39:30,936 --> 00:39:34,971 So they need to be lifted into position with cranes. 695 00:39:34,973 --> 00:39:36,206 Can I come around behind you? 696 00:39:36,208 --> 00:39:37,707 Sorry. Thanks very much. 697 00:39:37,709 --> 00:39:39,542 ♪ 698 00:39:39,544 --> 00:39:44,047 But the huge steel frame of the form traveler is in the way. 699 00:39:44,049 --> 00:39:47,217 So you can see the issues with getting the jacks 700 00:39:47,219 --> 00:39:48,952 Installed onto the bars. 701 00:39:48,954 --> 00:39:51,221 They've got very restricted access here 702 00:39:51,223 --> 00:39:53,123 With the frame of the form traveler, 703 00:39:53,125 --> 00:39:57,894 So it all has very, very intricate maneuvers here. 704 00:39:57,896 --> 00:40:00,530 Narrator: The team struggles to find a way through the frame 705 00:40:00,532 --> 00:40:02,499 Of the form traveler. 706 00:40:02,501 --> 00:40:05,935 With a little trial and error, they manage to thread the jack 707 00:40:05,937 --> 00:40:09,005 Through a tight gap down onto the first bar. 708 00:40:09,007 --> 00:40:11,207 The first line of bars to be tensioned 709 00:40:11,209 --> 00:40:13,042 Is this first line here, 710 00:40:13,044 --> 00:40:16,713 So he's just maneuvering the first jack into position now 711 00:40:16,715 --> 00:40:18,681 Over this first bar. 712 00:40:18,683 --> 00:40:20,784 But he's there now. 713 00:40:20,786 --> 00:40:22,118 Yeah. 714 00:40:22,120 --> 00:40:26,523 Nice job, so that's the first jack into position. 715 00:40:26,525 --> 00:40:29,058 Narrator: This is the critical moment everyone has been 716 00:40:29,060 --> 00:40:33,797 Working towards for more than three years. 717 00:40:33,799 --> 00:40:37,834 The jacks apply hundreds of tons of pressure to the steel bar 718 00:40:37,836 --> 00:40:40,770 To raise the concrete road below. 719 00:40:40,772 --> 00:40:44,207 And now this deck is coming up and closing this gap. 720 00:40:44,209 --> 00:40:47,076 Narrator: The powerful jack lifts the road deck 721 00:40:47,078 --> 00:40:48,611 Millimeter by millimeter. 722 00:40:48,613 --> 00:40:52,081 This gap is now probably about 40 millimeters, 723 00:40:52,083 --> 00:40:54,350 So the deck is still coming up. 724 00:40:54,352 --> 00:40:57,687 Narrator: Workers both above and below the concrete road 725 00:40:57,689 --> 00:41:01,658 Tighten nuts to lock the bridge deck higher and higher. 726 00:41:01,660 --> 00:41:03,259 The gap is getting a lot closer now, 727 00:41:03,261 --> 00:41:05,328 So we're getting there. 728 00:41:05,330 --> 00:41:09,299 We're still moving. 729 00:41:09,301 --> 00:41:11,534 Narrator: After only seven minutes, 730 00:41:11,536 --> 00:41:13,770 The jack has lifted the entire road 731 00:41:13,772 --> 00:41:16,940 By more than 15 inches. 732 00:41:16,942 --> 00:41:22,078 The decks are now locked and perfectly level. 733 00:41:22,080 --> 00:41:25,181 Wade: Really, really pleased to see it all come together. 734 00:41:25,183 --> 00:41:28,451 It's very, very satisfying for everybody. 735 00:41:28,453 --> 00:41:31,020 Narrator: With the roads now joined together, 736 00:41:31,022 --> 00:41:34,457 The team has finally bridged the barrow river. 737 00:41:34,459 --> 00:41:36,292 [ cheers and applause ] 738 00:41:39,564 --> 00:41:41,764 For the first time, 739 00:41:41,766 --> 00:41:45,635 It's possible to cross the bridge. 740 00:41:45,637 --> 00:41:48,571 This record-breaking crossing will provide a new route 741 00:41:48,573 --> 00:41:53,643 Across the barrow river for more than 12,000 vehicles every day. 742 00:41:53,645 --> 00:41:56,045 We'll be open to traffic very soon. 743 00:41:56,047 --> 00:42:00,283 I'm so proud and so pleased to have been part of this team 744 00:42:00,285 --> 00:42:02,452 That's been involved, loved it. 745 00:42:02,454 --> 00:42:04,954 Narrator: It's taken more than three years, 746 00:42:04,956 --> 00:42:08,925 But the barrow bridge is now finally complete. 747 00:42:08,927 --> 00:42:11,494 It will transform the southeast of ireland 748 00:42:11,496 --> 00:42:15,465 And the lives of everyone in the town of new ross. 749 00:42:15,467 --> 00:42:19,869 Bridges link people and link communities, 750 00:42:19,871 --> 00:42:21,504 And so actually, 751 00:42:21,506 --> 00:42:23,907 You leave more than the legacy of a physical structure. 752 00:42:23,909 --> 00:42:26,509 You leave united community. 753 00:42:26,511 --> 00:42:28,645 ♪ 67079

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