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
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.