Original subtitles

[dramatic music]

- [Narrator] Much more than merely large bridges,

they represent the technological benchmarks of their time,

epical statements, manifestos.

They are the most spectacular suspension bridges

on our earth,

monuments and essential mainstays of our infrastructure.

Daily they pave the way for us to move smoothly

from here to there to anywhere,

and it also makes them maintenance monsters.

- [Interpreter] It is really difficult

for us to get close to the bridge.

- [Narrator] Their steel cables are susceptible

to corrosion, especially if located in maritime regions.

This means that they constantly need to be serviced,

bringing benefits to some, of course.

- Who has an office like this, huh?

[men laughing]

- [Narrator] From day one, the challenges are enormous.

[dramatic music]

- [Interpreter] The weather was a big issue.

- [Narrator] A multimillion dollar game

that often drives the engineers to the verge

of bankruptcy and madness.

- [Interpreter] My concern was that

it would turn into a nightmare.

How do we solve this?

- [Narrator] These gigantic structures cross borders

and take lives.

The entire project, a constant balancing act.

[dramatic music]

But when they are completed,

opening new paths on a daily basis for millions of people,

all of a sudden there is only magic and pride.

- [Interpreter] It's magnificent.

- [Narrator] Giant suspension bridges,

the secrets behind the constructions,

their spectacular structure,

and the daily maintenance challenges.

"Gigantic Constructions,

The Most Spectacular Suspension Bridges in the World."

[upbeat techno music]

[upbeat music]

- [Narrator] Majestic,

gigantic,

unique.

Whatever superlative one chooses,

they are all justified,

but without a few key milestones

in the history of bridge construction,

they would all be inconceivable.

The first legendary suspension bridges,

like the Brooklyn Bridge, combines two elements,

long suspension ropes and inclined cables.

In the 1930s, the Golden Gate Bridge

surpasses for the first time a gigantic clear span.

80 years later,

bridge engineers push the boundaries even further.

Both in China and Russia,

records are broken within a short time of each other.

[dramatic music]

[whooshing]

San Francisco, Golden Gate Bridge,

an iconic landmark

and its construction providing the impetus

in the race of superlatives

towards ever longer,

more spectacular suspension bridges.

Today, a maintenance monster,

an extreme challenge on a daily basis.

Its construction pushed the limits.

[dramatic music]

[whooshing]

[dramatic music]

The most photographed bridge in the world.

[dramatic music]

It is both a landmark

and part of the essential infrastructure

in the middle of the Bay of San Francisco.

[dramatic music]

[computer beeps]

The Golden Gate Bridge on the USA's California coast.

Early morning, Chris Sermon and Chad Allen

start their shift.

The men are part of the Golden Gate's

38-member painting team.

They're responsible for the legendary color of the bridge.

Over decades, the distinctive red

has become the signature feature of the suspension bridge,

making it the superstar among bridges.

365 days a year, the maintenance professionals paint

over and over again.

- So this is where the job site is.

- [Narrator] The guys have been working

on the Golden Gate for 20 years,

always the same color, always the same bridge.

Doesn't it get boring?

- No, it's just that we have like 1.7 miles

of bridge to cover.

So within your career here,

you're not gonna paint the same thing twice.

- [Narrator] Throughout the year,

the crew uses about 19,000 liters

on approximately 72,000 tons of steel.

Official name of the reddish color, International Orange.

Is a different color even conceivable?

- No, no, no.

- I'd do kelly green, please, yes.

I'd love a nice Irish green.

[men laughing]

- [Narrator] With brushes and spray tank,

the men work in pairs.

Each step is doubly secured.

- That power wire usually gets caught on that outrigger

when we're going up.

Just keep an eye on it.

It can be very dangerous.

That's why, as you can see,

you know you gotta work together good with your partner,

and then once you like climb out on the steel,

you gotta make sure where your footing is at all times.

You want to make sure you know what you're standing on.

Good?

[machine whirring]

- [Narrator] It is the only way to preserve the bridge,

which was opened to traffic in 1937.

Daily painting all the time.

The maintenance team's greatest foe, rust.

The salt air attacks the bridge constantly.

Moisture and millions of tiny salt particles

are the perfect accelerators for corrosion.

Chris, Chad, and the rest of the crew

work at spectacular heights

for the preservation of the bridge.

The best way to describe the worker's process,

learning by doing.

The experienced colleagues show newcomers

how everything works.

For example, the climbing harness,

of vital importance to the painter's daily work routine,

especially on the mighty main cable

directly above the six-lane highway.

The men are constantly at work here.

The challenge, balancing with bucket and brush

in the unpredictable winds of the Pacific,

record-breaking routine on a bridge that holds many records.

[dramatic music]

The construction of the Golden Gate moves boundaries,

one superlative after another,

the highest,

the longest span,

the massive underwater foundation,

and the strongest steel cables,

the foundation, extremely challenging construction work.

[dramatic music]

[whoosing]

Ewa Bauer, the Golden Gate's current chief engineer,

knows exactly how hard the road to iconic landmark

in the case of the Golden Gate Bridge can be.

- In all, it was a marvelous engineering achievement.

What was difficult?

As you can imagine, the waves of the Pacific ocean

and all the really treacherous currents

that are constantly present in the Golden Gate Strait.

[whooshing]

- [Narrator] A gigantic challenge

from the base at a depth of 30 meters

to the strongest steel cables at that time.

[machine whirring]

The bridge, a technical masterpiece

of chief engineer Joseph Baermann Strauss.

129,000 kilometers of steel wire form the two main cables

that keep the road in a safe but flexible balance.

To compensate for hurricanes and earthquakes in the area,

the bridge swings up to eight feet on each side.

Strauss also revolutionizes

all hither to known safety concepts.

Nevertheless, between 1933 and 1937, 11 workers die.

Still, the pioneering achievement back then

can be considered a huge success.

[whooshing]

- The access trestle that was made out of wood

and constructed to build the south tower fender

was wiped out three times by strong storms,

and every time it was rebuilt.

And this is just one of the examples,

what people had to deal with

in realizing the idea that many doubted can be realized.

- [Narrator] But chief engineer, Joseph Baermann Strauss,

and his men persevere.

In May 1937, the bridge opens over the Golden Gate Bay

astounding the world.

With a 1,280 meter span,

it was the longest suspension bridge in the world.

335 meters off the coast,

a huge saison is lowered into the water.

This enables the foundation of the southern pier

to be grounded at a depth of 30 meters

in the event of strong currents.

[dramatic music]

[whooshing]

[dramatic music]

For the painting crew,

the Golden Gate Bridge with its gigantic proportions means

one thing and one thing only, a lot of work.

When one area is finished,

the next section is waiting each day.

Chris and his fellow crew members

work steadily with routine.

It is precisely that that represents the challenge.

- You don't rush it up there.

You take your time,

you know the work will still get done,

but you wanna be safe first, definitely so well,

it feels good when you come down,

it's done and you're back on the ground.

- [Narrator] The workers' concentration can never let up.

The rules are strict every two hours

they have to take a break

while operating on a tight schedule.

The team moves on to the next rust grid point,

this time to the middle of the bridge,

which is open for traffic.

Not an easy job to work directly

on a lively tourist attraction.

Onlookers, tourists

and bridge spotters constantly interrupting the workflow.

- Heading in for break one day

and you see someone sitting there prying off

a piece of paint from one of the cables

to take home as a souvenir.

I've seen that happen a couple of times.

[car engines roaring]

- [Narrator] There is not a lot of space

directly on the wind prone cable

of the suspension bridge,

which is why the crew works with limited equipment.

Chad and Chris take only the essentials with them.

Buckets with paint, brushes and sturdy safety belts.

[dramatic music]

The gigantic wire cables of a suspension bridge

are particularly susceptible to corrosion.

The crew is especially thorough here.

The monitoring of the bridge is also done with extreme care

as a tourist attraction,

a notorious place for potential suicides

and the latent threat of terror.

The Golden Gate Bridge is among

the most carefully monitored sites in America.

100s of surveillance cameras,

barriers and fences secure the area 24 hours a day.

All surveillance information comes together

at the desk of Lisa Locati

She heads the Bridges security staff.

24 hours a day her team has every angle in sight.

The strategy, a constant presence.

- We have a lot of officers that are out

either patrolling by vehicle

or patrolling on the sidewalks by bicycle

or a Cushman cart.

So we're pretty visible out there

and our presence is pretty well known.

- [Narrator] In addition to the dangers to the bridge,

Lisa and her team also keep a watchful eye on the weather

that is of particular importance

for the crews on duty out there.

- Wind speed's about gusting to 20.

Our workers are going out onto the span

and they can't work in certain areas

if the wind speed is over 30 miles an hour.

- [Narrator] Lisa Locati always has an eye on Chris

and his team.

If there is potential danger,

she warns the men and work is aborted.

Today everything is going according to plan

for the Golden Gate painting crew.

Relatively calm, no rain.

On days like these

there is no better workplace in the world

for many of the team.

- You feel alive with that wind blowing on you.

It's a good feeling.

Who has an office like this huh?

[men laughing]

- [Narrator] The Golden Gate Bridge spans

the San Francisco Bay, pioneering, innovative

and the beginning of a new era

in the construction of suspension bridges,

when all of a sudden everything seems possible.

[whooshing]

The Akashi-Kaikyo Bridge total length 3,911 meters,

built to withstand wind forces

of up to 300 kilometers per hour

in one of the worst typhoon regions in the world.

[dramatic music]

The greatest logistics performance in the history of Japan.

Approximately 2 million workers labored for 10 years.

[helicopter engine whirring]

The maintenance, a gigantic challenge

on one of the most spectacular suspension bridges

on the planet.

[computer beeping]

The Akashi-Kaikyo Bridge connects the two Japanese islands

of Honshu and Awashima, the strait of Akashi.

Previously, the only connection between the two islands

of Honshu and Awashima,

one of the most dangerous waterways in the world.

1000s of people die here killed in collisions.

The only way to avoid the dangerous heavy traffic,

a gigantic bridge structure, the Akashi-Kaikyo Bridge.

Six lanes directly over the Akashi waterway.

Since 1995, it allows more than 100,000 cars

to travel shore to shore over a distance of 3.9 kilometers.

The longest suspension bridge in the world.

A gigantic bridge construction

that must be constantly maintained.

A challenge in the face of extreme heights

of up to almost 300 meters above the open sea.

The inspection team led by Chief Nakamori are on their way

to check the safety anchors and bolts.

The lift goes all the way up to the top.

- [Interpreter] I have never felt more free

than when I stood on top of this bridge.

I was scared just a little bit, but the bridge is safe,

so I got over my initial fears.

- [Narrator] Inspection at the very top

never becomes a routine for this team.

This particular inspection is only scheduled twice a year.

It takes the team 20 minutes in the elevator

and up several flights of stairs

before they see daylight again.

They reach the connection platform suspended

between two bridge pillars by climbing through a hatch.

Up here, double and triple safety regulations apply,

because the inspection takes place on

the cables of the bridge at the very top

at about 300 meters.

[wind blowing] [metal door clanking]

A last steel chain separates the maintenance crew

from the impending dangerous inspection.

[chain clanking]

- [Interpreter] Noshigoto watch your step.

- [Narrator] Inspection on top of

one of the largest structures in the world,

[clanking]

and on one of the most extraordinary bridges

for the Akashi-Kaikyo Bridge by reason of its construction

is not just any old suspension bridge.

Many suspension bridges are built with large chain systems.

The Japanese engineers, on the other hand,

settled on using a special cable system

to bear the weight of the bridge.

Just one of these enormous steel cables

consists of 290 individual cables.

The cable system runs the entire length of the bridge.

[bright music]

[clanking]

The fact that the 290 individual cables themselves consist

of 1000s of individual wire bundles

adds to the enormous weight.

The cable system alone weighs 25,000 tons.

If one were to lay all the individual cables end-to-end,

one could circle the world seven times,

the longest cable state bridge in the world in its entirety

and its construction.

A pioneering achievement and it is also essential

for the Akashi-Kaikyo Bridge stands

in one of the world's most typhoon endangered regions.

Chief engineer called Kochino Fomoto

recalls that prior to construction,

one particular challenge dominated all other considerations.

- [Interpreter] The biggest challenge

was to build a wind resistant bridge,

because of the incredible length we had to manage somehow

that it can withstand the strong typhoons in the region.

We had to understand how the bridge behaves in wind

prior to construction.

- [Narrator] The biggest problem of all,

[clanking]

not only must the bridge withstand enormously strong winds,

but also must be sufficiently open

so that the winds are offered little surface resistance,

the possible solution, an open steel structure

beneath the roadway to ensure stability. [clanking]

In the end, the engineers decide upon this solution.

They believe that the steel structure beneath the bridge

will provide sufficient stability

and enable the Akashi-Kaikyo Bridge

to withstand wind speeds of up to 300 kilometers an hour

in an emergency.

[clanking]

For the design and development stage,

a custom wind tunnel is built enabling the mock-up

to be tested during enormous wind speeds.

Second challenge securing.

There is no stable bedrock able to carry the load

of the complete structure.

[clanking]

The solution, an anchor point on the mainland.

A gigantic steel skeleton with 230,000 cubic meters

of concrete is cast to withstand the load.

Both the roadway and the suspension. Bridge cables

run into the foundation,

altogether an incredibly sophisticated construction

that also helps to save costs.

However, the engineers make a mistake

that only later comes to light.

- [Interpreter] Another big problem reveals itself

after construction is complete for inspections,

our engineers must have access

to all areas of the structure.

It was then we realized we had a problem.

We should have done better.

The inspections are enormously expensive,

because of our oversight.

- [Narrator] So it makes maintenance work on the bridge

a real thrill.

The team moves across a 120 centimeter wide cable,

nearly 300 meters above sea level to perform the inspection.

[dramatic music]

- [Interpreter] Are all the boats in order over there?

Yes?

Okay, carry on.

- [Narrator] The inspection is going well.

The view makes up for the thrill of the job.

- [Interpreter] Everything is in order.

The bridge isn't currently in need of any repairs.

[dramatic music]

- [Narrator] End of a successful workday

on the Akashi-Kaikyo Bridge in Japan,

[dramatic music]

the longer suspension bridge in the world,

300 meters over the open sea, it gets higher, much higher.

[dramatic music]

The most impressive example can be found in Latin America,

more specifically in Mexico.

The Puente Baluarte the highest cable state bridge

in the world,

402 meters high.

This height ensures a place

in the Guinness Book of World Records.

The bridge's construction,

a feet of the highest category

built in the middle of nowhere.

[computer beeping]

El Puente Baluarte is located in northern Mexico.

[computer beeping]

The bridge is the core part of a 250 kilometer long highway

through the mountains of the Sierra Madre Occidental

in Western Mexico.

[dramatic music]

The bridge has been opened to traffic since 2012

after only five years of construction time.

Today the very first general inspection is pending.

[car engine roaring]

20 engineers and industrial climbers

want to check the condition of the piers,

among them engineers,

Martin Vasquez Garcia and Mario Hernandez Hendes.

- [Interpreter] Get the ropes out.

Let me see if the green rope is long enough.

- [Interpreter] First, we measure the cable length

to see if it is long enough

to make it all the way down.

Then we climb down to inspect the surface of the pillars.

[whooshing]

- [Narrator] Today's task, check the pillars

for possible damage.

You can't be afraid of heights in this job.

- [Interpreter] This isn't your everyday height

and therefore pretty dangerous.

It's quite extreme.

You have to have a capable team that brings endurance

to the table.

- [Narrator] If Martin has the physical condition,

we will see later.

He and his team want to inspect eight double pillars

and two pylons with eight sides each,

secured only by two ropes.

[airplane engine whirring]

- [Interpreter] Make sure the belt is tight.

- [Narrator] Climbing helmet,

harness, carabiners, descender,

Martin and Mario prepare for the first pillar.

- [Interpreter] Okay, let the ropes down.

Finished Mario.

The beginning of the descent is the most difficult.

You have to get out there

and just get used to the situation,

figure out the mechanisms.

Then you have the risk.

Once you begin to descent,

there is no getting back quickly.

You have to continue climbing down until the end.

- [Narrator] Martin has a lot of experience,

however, he has not scaled such a high pillar in a while.

- [Interpreter] Done.

- [Narrator] Martin and Mario slow their own weight

with a rope break, To determine how fast

they can let themselves down on the pillar.

[dramatic music]

They have to coordinate everything

with the visual inspection of the pillars,

hanging 30 feet above the ground.

[dramatic music]

An arduous job,

but honestly a no-brainer compared to the effort

that the engineers engage in to build this gigantic bridge

here in the middle of nowhere.

Engineer Salvador Sanchez Nunez leads the mega project

with up to 3,500 workers

and it begins like a tale out of the wild west.

- [Interpreter] We could only get within six kilometers

of the proposed construction site.

Then we had to leave the cars and continue on horseback.

When we got to this wall,

here where pillar number 12 now stands,

we thought to ourselves

this will be quite an interesting challenge.

- [Narrator] Before the bridge was constructed,

the landscape consisted of deep valleys and dense forests,

no infrastructure to speak of.

All the roads in the area were built by Nunez and his crew.

[clanking]

Every component, every tool was brought here from far away.

A town is erected for the workers.

To make matters worse,

the bridge is in an earthquake and hurricane zone.

[clanking]

- [Interpreter] I think you have to be a dreamer

in order to implement a project like this,

but I have concerns that it will all end in a nightmare.

How should I solve the problem?

What can I expect the next day?

[dramatic music]

- The main problem,

the excavators have to dig holes

for some of the basic foundations almost twice as deep.

Since the rock is very fragile

and provides too little support,

even construction of the diamond shaped pylons

is very elaborate.

They have to support a total of 152 stay cables

all at the height of over 400 meters, a world record.

[whooshing]

To this day,

the Puente Baluarte holds the record

and remains the highest located cable stay bridge

in the world.

- [Interpreter] Personally and as an engineer,

I am very proud of the first Guinness record

for work of this kind in Mexico.

It is an honor for me and I'm happy to pass it on.

It is absolutely fantastic.

- [Narrator] Work is in full swing.

It's the first major inspection after construction

on the bridge was completed.

- [Interpreter] We looked for small cracks.

We measured them and tag them

and then determine what measures need to be taken.

- [Narrator] The inspection of the pylon wall

takes several hours.

Every crack is tagged conscientiously by Martin

and Mario documents it all with his helmet cam,

noticing even the smallest fissures.

[dramatic music]

The men are working on the south side of the pier.

The midday sun has heated up the concrete.

The fact that Martin hadn't been able to inspect the area

in a while is taking its toll on him.

He's struggling with the heat,

which radiates off the concrete.

He needs a break and has to abseil.

[Martin grunting]

Luckily everything goes well.

Martin makes it down in the nick of time.

- [Interpreter] I'm fine.

I'm a little tired from the altitude.

The rope is so hard to hold.

The harness prevents blood circulation,

so after a while you feel dizzy and you start to swing back

and forth up there.

I haven't found anything on this side,

but we do have to check all four sides,

up silent over there

to do the same thing all over again.

Everything was fine here.

[dramatic music]

- [Narrator] For today Martin and Mario are finished,

but they still have a lot of work ahead of them.

It'll take eight months in total

to inspect this great bridge.

The Puente Baluarte is not the last superlative structure

to be constructed by bridge builders.

One of the latest is in China.

The Aizhai Bridge, 355 meters above Dehang Canyon

connects two tunnels with one another,

making it the highest tunnel to tunnel bridge in the world,

China's latest mega feet.

[bright music]

Maintenance, a pure thrill at dizzying heights

on one of the most spectacular suspension bridges

in the world.

[computer beeping]

The Aizhai Bridge is located in China's Hunan Province.

[dramatic music]

6:00 AM The Aizhai Bridge makes its way through

the typical dense morning fog.

The mountain range is known for extreme weather,

snow in winter, heat in summer,

an enormous challenge for both construction

and daily maintenance,

all in the middle of nowhere in China.

[dramatic music]

The Aizhai province lies 20 minutes outside of Yeshu,

a small city by Chinese standards. With 300,000 inhabitants.

Ever since cars populated the area,

it has been a problem for years.

Drivers have had to navigate the extreme mountain roads,

also during precarious weather situations

to get from Yeshu to the next city Shandong.

The valley also represents a main transit route

and the only direct way

to get from central China to southern China.

Although the location is extremely unfavorable,

there is only one solution.

A bridge, a mega bridge in fact, the enormous size,

1,534 meters long and 355 meters above the valley,

one of the highest bridges in the world.

[bright music]

Xang Chi, the manager of the Aizhai Bridge,

is one of the few who always believed

in the successful construction of the bridge

and fights hard for it.

[dramatic music]

- [Interpreter] The bridge is the only connection

between central China and South China.

An important route for freight trucks, without this bridge

traffic would be pure chaos.

That is why we have fought against the odds.

- [Narrator] A bridge in this exposed position

with these measurements, for many, almost unimaginable.

[dramatic music]

But since the official opening at the end of March, 2012,

cars and trucks roll over the imposing structure.

The Aizhai Bridge is the highest bridge in the world

connecting two tunnels.

A total of four tracks shorten the actual journey time

through the valley many times over.

As one of the highest bridges in the world,

it is extremely vulnerable,

also because of the unpredictable weather,

requiring constant maintenance.

Responsibility lies with Mr. Zuhi

who holds a briefing at the control center.

- [Interpreter] During the last visual inspection,

we detected problems with the bridge suspension

on the lower deck and we now need to check it again.

We need to pay particular attention to safety.

The height poses extreme danger.

- [Narrator] This means the maintenance crew

has to check for rust

and the securing nuts and bolts,

in addition, examine the cable suspension for cracks.

The slightest damage could have huge consequences

for the safety of the bridge.

Zuhi's three member team make their way to the bridge,

10 minutes away.

Visual inspections on the bridge

are carried out almost daily.

If problems are discovered, Zuhi's team is called upon

to make an exact diagnosis.

- [Interpreter] We need to pay particular attention

to safety.

We work in nearly 350 meters height

and the slightest mistake could be fatal.

- [Narrator] The team moves under the bridge

in a huge steel cage, still on safe ground.

They climb on the steel beams.

Every time it's an adrenaline kick that you can't train for.

- [Interpreter] Can you hand me the hammer please?

- [Narrator] If Mr. Zuhi and his men actually discover

significant damage, they need to resolve

and repair in a timely manner.

The clear order from the top,

everything must be done to keep the main transport artery

of the region possible.

[clanking] [dramatic music]

Construction of the bridge takes five years,

cost $610 million.

Costs would've been considerably higher if the developers

had not landed a major breakthrough during the construction

of the two main pillars.

The existing mountains are used as a foundation,

concrete providing additional stabilization of the pillars.

[clanking]

It is the first time that a bridge in China

is built this way, so it is possible to keep the costs low,

but there are difficulties.

Since no one knows beforehand

that the slope which is expected to support the bridge

has its drawbacks.

- [Interpreter] At the start of foundation construction,

we discovered 18 small caves inside the mountain.

They didn't make our lives easier,

and the weather has played a crucial role.

Snow and rain have made construction work

a permanent challenge.

- [Narrator] The construction crew

use a total of 180,000 tons of material.

A special elevator is developed for that purpose.

[dramatic music]

Back to the inspection team,

the men are still busy checking everything

with the greatest accuracy and precision.

- [Interpreter] Everything still looks pretty good,

but we have to check the cable anchors

on the bridge in a moment.

- [Narrator] A thrill, even after five years on the job,

yet first Chief Inspector Zuhi

must take a step backwards for safety's sake.

Even after five years on the job, a real adrenaline kick.

- [Interpreter] Wow, I'm really happy

to be back on sturdy ground.

The height is always a big strain.

I love my job, but I prefer not to look down.

- [Narrator] The maintenance work is not yet done.

The Aizhai Bridge is currently

the highest suspension bridge running over an open valley.

[car engines roaring]

The individual cables

have to withstand extremely heavy loads.

Each cable consists of 169 individual cables.

[car engines roaring]

The anchoring of the cables on the bridge

are last on the inspection team's list.

After that, the crew can relax.

- [Interpreter] I'm proud to work here, over time,

you get used to the altitude and I consider it a privilege

to be able to stand here, not many can say that.

[dramatic music]

- [Narrator] It's the end of the workday

in the Aizhaie mountains in China,

on one of the highest

and most spectacular bridges in the world.

A suspension bridge,

which impressively demonstrates what engineers

are able to do worldwide.

In China, for example, but also in Russia.

It is there that another very spectacular example

of a gigantic bridge construction stands.

[dramatic music]

It is one of the largest bridges in the world.

The Russky Bridge, 1,104 meters lie between the two pylons.

That is a world record,

at least among the cable stay bridges,

and it was built in record time.

[computer beeping]

On the Eastern Bosphorus,

the Russky Bridge connects the mainland Vladivostok

to the Russky Islands.

Here on the Eastern Bosphorus in Vladivostok,

rough Pacific air prevails,

extreme drops in temperature within a short time

is not uncommon.

Then we have snow storms sweeping across the bridge.

This type of climate makes the Russky Bridge

a maintenance monster.

In any case,

the crew of the Russky Bridge must be weatherproofed.

There is always something to do on the bridge.

Oleg Zegaiov works here since the bridge is opening,

almost every day, regardless of wind and weather,

he is checking the condition of the bridge.

- [Interpreter] There are certain specifications

as to how far the seams may expand.

If the seams expand too far, the bridge is too loose,

too tight, it would not be able to withstand the vibrations.

Precision work is imperative here.

- [Narrator] A special focus is on the expansion joints.

They are the heart of the bridge,

with a width of 23.5 meters,

they are the largest expansion joints

that have ever been used in bridge construction,

the team check them daily.

All good.

The condition of proximity is correct,

but Oleg will discover something today

which causes him concern.

The bridge has other sensitive locations as well,

for example, the main pillars of the bridge,

a special team is on the way to the checkpoints.

However, you can only reach the zone by abseiling.

- [Interpreter] At 15 Kilometers wind speed,

it's not a problem.

[dramatic music]

- [Narrator] The climbing unit does the checks

at the very top of the pylon,

but today it is too foggy and windy.

However, the lower part should not be a problem.

[dramatic music]

- [Interpreter] No, I'm not afraid.

I love it.

The adrenaline kick, I need it

and there's always something to do.

- [Narrator] Today adrenaline kick, guaranteed.

The weather is deteriorating fast, becoming unpredictable.

It's no easy task for the pair.

[dramatic music]

At the same time, Oleg and his crew

clamber underneath the roadway and look around.

This is less dangerous than it would seem,

as they use a mobile maintenance platform

for their inspection,

which enables them to pass along a large part

of the bridge from underneath.

They look around very closely for the air,

heavy with moisture and salt particles

and the strong winds are putting great pressure

on the bridge's metal structure.

- [Interpreter] I'm already in the midst of it.

First I have to monitor

the so-called visual measurement control

where I have to look very carefully if I notice something.

- [Narrator] The question is what they see,

only dirt or is there real damage?

Oleg is searching for the smallest traces of corrosion.

- [Interpreter] Stop for a second.

[wind blowing]

These may look small,

but little defects are easier to repair,

therefore, avoiding larger repairs in the future.

In such harsh conditions,

a small defect can quickly turn into something much bigger.

- [Narrator] Oleg keeps discovering irregularities

even though the bridge is practically new.

[dramatic music]

Russky Bridge is completed in 2012

after only three years of construction

at temperatures of sometimes minus 40 degrees Celsius,

the work week is on a 24/7 basis

that comes with a hefty price tag,

alleged total costs of nearly 1 billion Euros.

It is mainly due to the short construction time

and the extreme climatic conditions.

Edouard Shumakov head of public transport

is responsible for the project.

- [Interpreter] It's a special place due to climatic

and geologic features.

This finds expression in seismic activities

and was considered during the development.

We were able to calculate how the bridge

should withstand vibrations

together with a very precise model

and that was realized during the construction.

[clanking] [dramatic music]

- [Narrator] For the design and construction,

earthquake protection is a big issue.

Here the bridge deck is like a big pendulum

suspended on the ropes.

[dramatic music]

At the end of the pendulum,

six meter long shock absorbers have been installed.

They help protect against tremors and against the extreme winds.

Each cable also has its own shock absorber.

Some of these can even measure vibrations

and adjust their absorbing force accordingly.

A gigantic structure and a billion dollar investment,

but for what?

[clanking]

At the time of construction,

only 5,000 people were living on the peninsula

where the bridge ends. [dramatic music]

[clanking]

[dramatic music]

The occasion for the launch of construction work is to serve

the Asia Pacific Economic Cooperation Conference,

one of the mandates connecting the island.

Meanwhile, the island boasts a university

and some laboratories.

There are plans to boost tourism here

as well as making the bridge a costly transit hub.

[dramatic music]

During inspection underneath the bridge

Oleg discover something.

- [Interpreter] Sonic stop here for a minute.

You can see right away this is still from the construction,

they botched it,

which means it's a case of warranty.

The construction company has to repair the damages for free.

I will report this immediately, okay, good?

Let's go back now.

- [Narrator] The bottom line,

here the construction companies

have obviously applied too little anti corrosion protection.

In this climate this can quickly lead to serious damage.

Oleg knows exactly what it means if he overlooks a defect.

The same applies to his colleagues who are on route

to one of the pylon bases on the underside of the bridge.

The two men have been in the air for some time

and due to the difficult conditions, progress is slow.

It demands great effort,

but they want to complete the inspection at all costs.

[dramatic music]

Done, the next stage of the pylon base inspection

will be easier with firm ground beneath their feet.

Important, after such an exhausting descent.

Now for a careful look around.

- [Interpreter] Wow check this out.

Good thing we have a camera.

It looks pretty bad.

- [Narrator] Although the bridge

has not long been in operation,

it is already showing some signs of wear and tear,

salt, the permanently strong wind

and extreme temperature fluctuations,

for every bridge a nightmare,

and now the weather is shifting again.

- [Interpreter] What was that?

The storm's getting worse.

Let's get out of here before it becomes too dangerous.

- [Narrator] The men decide to beat a retreat.

The risks today are just too great.

A premature disruption of the inspection.

No rarity here in the Eastern Bosporus.

[dramatic music]

If the weather improves,

the inspection will possibly continue tomorrow.

Daily routine on the Russky Bridge, without doubt,

one of the most gigantic

and spectacular suspension bridges in the world.

[dramatic music]