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These are the user uploaded subtitles that are being translated: 1 00:00:01,568 --> 00:00:04,569 -- Captions by VITAC -- www.vitac.com 2 00:00:04,570 --> 00:00:07,607 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:52,183 --> 00:00:54,986 Narrator: THE DECK OF A RAILWAY BRIDGE 4 00:00:54,987 --> 00:00:58,324 IS TYPICALLY BUILT OF WOOD-TIMBERS CALLED BRIDGE TIES. 5 00:00:58,325 --> 00:01:00,624 THEY'RE BOLTED TO STEEL SUPPORT BEAMS 6 00:01:00,625 --> 00:01:04,363 LOCATED ON CONCRETE PIERS OVER THE WATER OR GULLY BELOW. 7 00:01:04,364 --> 00:01:06,264 THE RAILS ON WHICH THE TRAIN TRAVELS 8 00:01:06,265 --> 00:01:08,133 ARE BOLTED TO THE WOODEN TIES. 9 00:01:08,134 --> 00:01:10,200 WOOD ABSORBS THE NOISE AND VIBRATION 10 00:01:10,201 --> 00:01:11,771 OF THE PASSING TRAIN. 11 00:01:14,739 --> 00:01:16,741 THE LOAD THE RAILWAY BRIDGE WILL CARRY 12 00:01:16,742 --> 00:01:18,943 DETERMINES THE SIZE OF ITS TIES. 13 00:01:18,944 --> 00:01:20,646 TO CALCULATE THE LOAD, 14 00:01:20,647 --> 00:01:23,315 ENGINEERS FACTOR IN THE NUMBER OF TRACKS, 15 00:01:23,316 --> 00:01:27,051 VOLUME OF TRAFFIC, WEIGHT OF THE TRANSPORTED CARGO, 16 00:01:27,052 --> 00:01:30,889 AND WHETHER THE BRIDGE IS STRAIGHT OR CURVED. 17 00:01:30,890 --> 00:01:34,792 A CURVE WILL PUT ADDITIONAL STRESS ON THE STRUCTURE. 18 00:01:34,793 --> 00:01:39,264 THE WOOD OF CHOICE IS OAK BECAUSE IT'S HARD AND STRONG. 19 00:01:39,265 --> 00:01:41,232 WHEN THE LOGS ARRIVE AT THE SAWMILL, 20 00:01:41,233 --> 00:01:43,935 THEY COME FACE-TO-FACE WITH A MENACING-LOOKING DEVICE 21 00:01:43,936 --> 00:01:45,805 CALLED A DEBARKER. 22 00:01:47,373 --> 00:01:51,176 A CONVEYOR MOVES THE SHIPMENT TOWARD THE DEBARKER, 23 00:01:51,177 --> 00:01:55,682 THEN DROPS A SINGLE LOG IN FRONT OF IT ONTO SPINNING ROLLERS. 24 00:01:57,483 --> 00:02:00,485 THE ROLLERS ROTATE THE LOG, 25 00:02:00,486 --> 00:02:03,889 WHILE THE DEBARKER MAKES ITS WAY FROM ONE END TO THE OTHER. 26 00:02:03,890 --> 00:02:07,893 IT CHEWS OFF THE BARK WITH ITS SHARP-TOOTHED BLADES. 27 00:02:10,329 --> 00:02:13,698 WHAT THE DEBARKER SHAVES OFF IS PUT TO GOOD USE. 28 00:02:13,699 --> 00:02:16,736 THE BARK GETS PROCESSED INTO GARDENING MULCH 29 00:02:16,737 --> 00:02:19,505 AND THEY BURN THE SAWDUST IN THE WOOD-FIRED BOILER 30 00:02:19,506 --> 00:02:21,574 THAT RUNS ANOTHER PART OF THE PLANT. 31 00:02:24,276 --> 00:02:27,712 NEXT, ONE LOG AT A TIME DROPS INTO A MOBILE CARRIAGE 32 00:02:27,713 --> 00:02:30,715 THAT RUNS IT THROUGH A CIRCULAR SAW. 33 00:02:30,716 --> 00:02:32,051 THE CARRIAGE HAS SENSORS 34 00:02:32,052 --> 00:02:34,418 WHICH DETECT THE LOG'S EXTREMITIES 35 00:02:34,419 --> 00:02:35,721 AND REPORT ITS DIMENSIONS 36 00:02:35,722 --> 00:02:39,357 TO A CONSOLE LOCATED IN THE OPERATOR'S CAB. 37 00:02:39,358 --> 00:02:41,793 THE OPERATOR INTERPRETS THE DATA. 38 00:02:41,794 --> 00:02:43,529 USING A JOYSTICK CONTROLLER, 39 00:02:43,530 --> 00:02:45,829 HE FLIPS THE LOG INTO WHICHEVER POSITION 40 00:02:45,830 --> 00:02:47,699 MAXIMIZES THE YIELD. 41 00:02:50,169 --> 00:02:51,502 THE FIRST FEW RUNS 42 00:02:51,503 --> 00:02:55,273 TRIM OFF THE ROUGH SURFACE AND SQUARE THE SHAPE. 43 00:02:55,274 --> 00:02:57,241 THE NEXT RUNS CUT BOARDS, 44 00:02:57,242 --> 00:03:00,077 WHICH THE SAWMILL SELLS TO FLOORING PLANTS. 45 00:03:00,078 --> 00:03:03,247 THIS CONTINUES UNTIL THE LOG IS THE EXACT DIMENSIONS 46 00:03:03,248 --> 00:03:05,782 OF THE BRIDGE TIE. 47 00:03:05,783 --> 00:03:08,353 AGAIN, NOTHING IS WASTED. 48 00:03:08,354 --> 00:03:11,624 THE SAWMILL PROCESSES THE CUTOFFS INTO WOOD CHIPS, 49 00:03:11,625 --> 00:03:14,625 WHICH IT THEN SELLS TO COMPANIES THAT MAKE PARTICLE BOARD, 50 00:03:14,626 --> 00:03:18,431 STRAND BOARD, AND SIMILAR CONSTRUCTION MATERIALS. 51 00:03:20,500 --> 00:03:22,267 THE SAWMILL STACKS THE TIES 52 00:03:22,268 --> 00:03:24,734 FOR TRANSFER TO THE BRIDGE MILL NEXT DOOR. 53 00:03:24,735 --> 00:03:28,239 THE ROLE OF THE BRIDGE MILL IS TO FRAME THE BRIDGE, 54 00:03:28,240 --> 00:03:30,541 ALSO KNOWN AS DAPPING. 55 00:03:30,542 --> 00:03:33,611 THAT'S THE PROCESS OF MAKING THE SPECIFIC HOLES 56 00:03:33,612 --> 00:03:35,145 AND NOTCHES IN EACH TIE 57 00:03:35,146 --> 00:03:38,717 FOR ATTACHING IT TO THE STEEL BEAM ON WHICH IT WILL SIT. 58 00:03:41,353 --> 00:03:42,819 AT THE BRIDGE MILL, 59 00:03:42,820 --> 00:03:47,057 THE BRIDGE LAYOUT SUPERVISOR PROCESSES ONE TIE AT A TIME. 60 00:03:47,058 --> 00:03:49,793 HE CAREFULLY REVIEWS THE ENGINEER'S BLUEPRINTS, 61 00:03:49,794 --> 00:03:52,563 WHICH ASSIGN A NUMBER TO EACH AND EVERY TIE. 62 00:03:52,564 --> 00:03:57,202 THESE NUMBERS SPECIFY PRECISELY WHERE THE SAW HAS TO CUT NOTCHES 63 00:03:57,203 --> 00:04:00,071 AND WHERE THE DRILL HAS TO BORE HOLES. 64 00:04:00,072 --> 00:04:02,240 THE LOCATIONS OF THESE NOTCHES AND HOLES VARY, 65 00:04:02,241 --> 00:04:04,809 DEPENDING ON THE TIE'S POSITION ON THE BRIDGE. 66 00:04:04,810 --> 00:04:08,146 SO, HE MUST FOLLOW THE BLUEPRINTS METICULOUSLY. 67 00:04:10,316 --> 00:04:12,652 AFTER MEASURING AND MARKING IT ALL OUT, 68 00:04:12,653 --> 00:04:16,287 HE SENDS THE TIE TO THE DAP SAW. 69 00:04:16,288 --> 00:04:18,123 THE OPERATOR SETS UP EACH CUT, 70 00:04:18,124 --> 00:04:19,958 LINING UP THE MARK WITH LASER-LIGHTS, 71 00:04:19,959 --> 00:04:22,193 WHICH INDICATE THE LOCATION AND THE CUTTING DEPTH 72 00:04:22,194 --> 00:04:23,629 OF THE BLADE. 73 00:04:37,475 --> 00:04:40,845 THE NOTCHES ARE JUST THE RIGHT SIZE TO FIT OVER THE STEEL BEAM 74 00:04:40,846 --> 00:04:42,915 ON WHICH THE TIE WILL LIE. 75 00:04:44,483 --> 00:04:47,219 NEXT, A WORKER USING A DRILL PRESS 76 00:04:47,220 --> 00:04:49,955 BORES HOLES FOR HOOK BOLTS, WHICH GO THROUGH THE TIE 77 00:04:49,956 --> 00:04:52,591 TO SECURE IT ONTO THE STEEL BEAMS. 78 00:04:54,526 --> 00:04:57,929 EACH TIE RECEIVES A METAL IDENTIFICATION TAG, 79 00:04:57,930 --> 00:05:02,266 WHICH INCLUDES THE BRIDGE AND TIE NUMBERS. 80 00:05:02,267 --> 00:05:05,304 ON EACH END, WORKERS NAIL ON A MESH PLATE, 81 00:05:05,305 --> 00:05:08,306 MADE OF RUST-PROOF GALVANIZED STEEL. 82 00:05:08,307 --> 00:05:11,241 THE PLATE HAS TEETH DESIGNED TO GRASP AND HOLD TOGETHER 83 00:05:11,242 --> 00:05:15,179 THE WOOD FIBER TO PREVENT THE END FROM SPLITTING. 84 00:05:15,180 --> 00:05:18,383 AFTER NAILING THE ID TAG TO ONE OF THE END PLATES, 85 00:05:18,384 --> 00:05:21,754 WORKERS FORCE IN BOTH PLATES WITH A PRESS. 86 00:05:26,459 --> 00:05:30,427 THE TIE'S LAST STOP IS THE ADJACENT TREATMENT PLANT. 87 00:05:30,428 --> 00:05:33,397 THEY SPEND 24 HOURS INSIDE A HIGH-TEMPERATURE, 88 00:05:33,398 --> 00:05:34,866 HIGH-PRESSURE CHAMBER 89 00:05:34,867 --> 00:05:38,736 WHICH PENETRATES THEM WITH A CREOSOTE-BORATE SOLUTION. 90 00:05:38,737 --> 00:05:41,873 THIS PROTECTS THE WOOD FROM ROT AND INSECT DAMAGE 91 00:05:41,874 --> 00:05:43,743 AND EXTENDS THE TIE'S LIFE-SPAN 92 00:05:43,744 --> 00:05:48,247 FROM ABOUT A DECADE TO AT LEAST 25 YEARS. 93 00:05:59,000 --> 00:06:00,201 Narrator: WHEN FILTERING LIQUIDS, 94 00:06:00,202 --> 00:06:02,002 IT'S ALL ABOUT THINKING SMALL. 95 00:06:02,003 --> 00:06:05,973 MEMBRANE FILTERS CAN SEPARATE THE TINIEST SOLIDS FROM FLUIDS, 96 00:06:05,974 --> 00:06:09,511 WHICH PURIFIES THE LIQUIDS AND RECOVERS THE SOLIDS. 97 00:06:09,512 --> 00:06:11,814 ONCE SEPARATED, THE TWO SUBSTANCES 98 00:06:11,815 --> 00:06:16,051 MAY THEN BE REUSED SO THAT NOTHING GOES TO WASTE. 99 00:06:20,289 --> 00:06:25,327 MEMBRANE FILTERS CAN TURN MURKY WATER CLEAR, ALMOST MAGICALLY. 100 00:06:27,330 --> 00:06:30,932 TO DEMONSTRATE, A TECHNICIAN INSTALLS A SPIRAL-WOUND MEMBRANE 101 00:06:30,933 --> 00:06:33,201 IN THE HOUSING OF A PUMPING SYSTEM, 102 00:06:33,202 --> 00:06:34,670 WHICH IS A SMALL-SCALE VERSION 103 00:06:34,671 --> 00:06:38,240 OF WHAT YOU WOULD SEE IN A FACTORY. 104 00:06:38,241 --> 00:06:42,110 SHE TURNS ON THE TAP, AND WATER FLOWS INTO A TANK. 105 00:06:42,111 --> 00:06:45,815 SHE ADDS LATEX PAINT TO PURPOSELY SULLY THE WATER. 106 00:06:48,183 --> 00:06:50,384 THE SYSTEM PUMPS THE CONTAMINATED WATER 107 00:06:50,385 --> 00:06:51,886 THROUGH A STRAINER 108 00:06:51,887 --> 00:06:57,091 AND THEN THE MEMBRANE FILTER WHILE METERS MEASURE THE FLOW. 109 00:06:57,092 --> 00:06:59,694 WITHIN MINUTES, THE PAINT HAS BEEN FILTERED OUT, 110 00:06:59,695 --> 00:07:01,863 AND THE WATER IS CLEAR. 111 00:07:03,197 --> 00:07:07,837 THE MAKING OF A MEMBRANE FILTER BEGINS WITH POLYPROPYLENE MESH. 112 00:07:11,274 --> 00:07:15,643 AN AUTOMATED SYSTEM UNWINDS THE MESH AND CUTS IT TO LENGTH. 113 00:07:15,644 --> 00:07:19,182 THESE MESH SHEETS WILL BE USED AS SPACERS. 114 00:07:20,383 --> 00:07:22,583 THEY'LL CREATE GAPS FOR THE LIQUID 115 00:07:22,584 --> 00:07:25,587 TO FLOW THROUGH THE FILTER AND OVER THE MEMBRANE. 116 00:07:26,589 --> 00:07:29,958 NEXT, THE SYSTEM CUTS SHEETS OF POLYESTER FABRIC. 117 00:07:29,959 --> 00:07:31,494 THESE WILL FORM CHANNELS 118 00:07:31,495 --> 00:07:34,463 THROUGH WHICH THE FILTERED MATERIAL WILL TRAVEL. 119 00:07:34,464 --> 00:07:38,266 THESE SHEETS ARE KNOWN AS PERMEATE SPACERS. 120 00:07:38,267 --> 00:07:42,336 AN EMPLOYEE STACKS THE POLYESTER FABRIC SHEETS. 121 00:07:42,337 --> 00:07:44,572 USING HIGH-FREQUENCY SOUND WAVES, 122 00:07:44,573 --> 00:07:48,277 SHE WELDS ONE SHEET TO THE NEXT AT JUST ONE END. 123 00:07:51,214 --> 00:07:54,816 SHE LAYERS AND WELDS A TOTAL OF 15 SHEETS, 124 00:07:54,817 --> 00:07:56,852 AND THEN APPLIES DOUBLE-SIDED TAPE. 125 00:07:56,853 --> 00:08:00,054 THE TAPE IS FOR ATTACHING THE PACKET TO A CENTRAL TUBE, 126 00:08:00,055 --> 00:08:03,959 AND IT WILL ALSO SERVE AS A GUIDE TO CORRECTLY ALIGN IT. 127 00:08:07,296 --> 00:08:11,132 NEXT, THE MEMBRANE SOUP FLOWS INTO A LONG TROUGH. 128 00:08:11,133 --> 00:08:15,470 IT'S A MIX OF MELTED PLASTICS AND SOLVENTS. 129 00:08:15,471 --> 00:08:18,506 PAPER BACKING UNWINDS INTO THE TROUGH 130 00:08:18,507 --> 00:08:22,276 AND IS COATED WITH THE SOUP ON ONE SIDE. 131 00:08:22,277 --> 00:08:25,446 THE COATED PAPER THEN TRAVELS THROUGH TWO QUENCH TANKS, 132 00:08:25,447 --> 00:08:28,016 AND THE PLASTIC COMPONENTS SOLIDIFY 133 00:08:28,017 --> 00:08:30,352 AS THE SOLVENTS ARE DRAWN OUT. 134 00:08:30,353 --> 00:08:33,356 THE EXITING SOLVENTS CREATE A UNIQUE CORE STRUCTURE 135 00:08:33,357 --> 00:08:36,592 IN THE REMAINING WHITE PLASTIC MEMBRANE. 136 00:08:36,593 --> 00:08:39,294 THE MEMBRANE NOW TRAVELS BY A LIGHT BOX, 137 00:08:39,295 --> 00:08:42,664 WHICH ILLUMINATES ANY VISUAL DEFECTS. 138 00:08:42,665 --> 00:08:47,234 AN APPLICATOR ALSO DRIPS A PRESERVATIVE ONTO THE MEMBRANE. 139 00:08:47,235 --> 00:08:50,939 A TEAM UNROLLS THE MEMBRANE ONTO A WORK TABLE. 140 00:08:53,209 --> 00:08:55,678 THEY LAY A SHEET OF THE POLYPROPYLENE MESH, 141 00:08:55,679 --> 00:08:59,414 WHICH WE SAW CUT TO SIZE EARLIER, ON THE MEMBRANE. 142 00:09:02,084 --> 00:09:04,520 THE EMPLOYEE THEN CUTS THE MEMBRANE 143 00:09:04,521 --> 00:09:07,222 TO TWICE THE LENGTH OF THE MESH. 144 00:09:07,223 --> 00:09:09,189 THEY FOLD THE MEMBRANE OVER THE MESH, 145 00:09:09,190 --> 00:09:11,593 CREATING A MEMBRANE ENVELOPE. 146 00:09:11,594 --> 00:09:13,661 THE MESH SERVES AS A PATHWAY FOR FLUID 147 00:09:13,662 --> 00:09:16,231 TO FLOW BETWEEN THE MEMBRANES. 148 00:09:19,301 --> 00:09:20,868 MEANWHILE, ANOTHER WORKER 149 00:09:20,869 --> 00:09:24,573 APPLIES EPOXY TO PERFORATED PLASTIC TUBE. 150 00:09:24,574 --> 00:09:26,875 HE ATTACHES THE PERMEATE SPACERS TO IT 151 00:09:26,876 --> 00:09:28,443 WITH THE DOUBLE-SIDED TAPE, 152 00:09:28,444 --> 00:09:32,315 GIVING THE EPOXY TIME TO CURE FOR A PERMANENT SEAL. 153 00:09:34,148 --> 00:09:36,417 HE AND A COLLEAGUE APPLY MORE EPOXY 154 00:09:36,418 --> 00:09:39,787 TO THE PERIMETER OF THE BOTTOM SHEET. 155 00:09:39,788 --> 00:09:41,756 THEY TRANSFER THE MEMBRANE ENVELOPE TO IT 156 00:09:41,757 --> 00:09:43,558 AND CONTINUE TO LAYER, 157 00:09:43,559 --> 00:09:46,663 MAKING A PERMEATE FABRIC AND MEMBRANE SANDWICH. 158 00:09:50,233 --> 00:09:52,666 THE WORKER THEN WINDS THE GLUED LAYERS SNUGGLY 159 00:09:52,667 --> 00:09:54,803 TO A PERFORATED PLASTIC CORE, 160 00:09:54,804 --> 00:09:57,540 FORMING THE SPIRAL MEMBRANE FILTER. 161 00:09:59,307 --> 00:10:03,044 HE TAPES THE MULTI-LAYERED WAD FROM ONE END TO THE OTHER. 162 00:10:03,045 --> 00:10:05,213 THE TAPE HOLDS EVERYTHING TIGHTLY IN PLACE 163 00:10:05,214 --> 00:10:07,883 AS THE EPOXY CURES OVERNIGHT. 164 00:10:09,352 --> 00:10:11,754 THEY LEAVE THE TAPE ON AFTER THE CURE, 165 00:10:11,755 --> 00:10:14,588 AND A MACHINE WINDS EPOXY-DRENCHED FIBERGLASS ROPE 166 00:10:14,589 --> 00:10:16,723 AROUND THE ENTIRE FILTER. 167 00:10:16,724 --> 00:10:19,761 AS THE EPOXY CURES, 168 00:10:19,762 --> 00:10:24,465 THE ROPE WILL FORM A HARD SHELL AROUND THE MEMBRANE FILTER. 169 00:10:24,466 --> 00:10:25,933 PARTWAY THROUGH, 170 00:10:25,934 --> 00:10:28,504 THEY APPLY THE LABEL WITH A COMPANY NAME. 171 00:10:31,806 --> 00:10:37,279 THE OPERATOR CAPTURES THE GLUE RUNOFF DURING THE WIND. 172 00:10:37,280 --> 00:10:40,183 AND IT'S A WRAP, SO HE CUTS THE ROPE. 173 00:10:42,384 --> 00:10:44,419 FROM THE SIDE, YOU CAN SEE THE FLOW CHANNELS 174 00:10:44,420 --> 00:10:46,487 BETWEEN THE LAYERS. 175 00:10:46,488 --> 00:10:50,257 CONCENTRATED CONTAMINANTS WILL TRAVEL THROUGH THEM AND OUT. 176 00:10:50,258 --> 00:10:53,761 THE FILTERED LIQUID WILL SEEP INTO THE CORE AND EXIT, 177 00:10:53,762 --> 00:10:55,964 CLEARLY IMPROVED. 178 00:11:04,550 --> 00:11:06,218 Narrator: THE INVENTION OF THE HYDRAULIC POST DRIVER 179 00:11:06,219 --> 00:11:07,819 IN THE 1960s 180 00:11:07,820 --> 00:11:10,756 ALLOWED WORKERS TO DROP THEIR SHOVELS AND SLEDGEHAMMERS 181 00:11:10,757 --> 00:11:13,860 AND LET A MACHINE DO THE JOB OF POUNDING FENCE AND SIGN POSTS 182 00:11:13,861 --> 00:11:15,328 INTO THE GROUND. 183 00:11:15,329 --> 00:11:17,929 WHEN IT COMES TO LABOR-SAVING INVENTIONS, 184 00:11:17,930 --> 00:11:21,267 THIS ONE IS DEFINITELY A STRIKING EXAMPLE. 185 00:11:24,837 --> 00:11:26,771 THE POST DRIVER 186 00:11:26,772 --> 00:11:30,509 RAISES HEFTY FENCE OR SIGN POSTS INTO POSITION, 187 00:11:30,510 --> 00:11:33,881 AND THEN SLAMS THEM INTO THE GROUND. 188 00:11:37,284 --> 00:11:40,986 INSIDE A VERTICAL CASE, A HYDRAULIC SYSTEM 189 00:11:40,987 --> 00:11:43,722 DROPS A 300-POUND WEIGHT TO DRIVE THE POST, 190 00:11:43,723 --> 00:11:45,691 AND THEN LIFTS IT FOR ANOTHER HIT. 191 00:11:49,429 --> 00:11:52,798 THIS MACHINE DOES THE WORK OF TWO OR MORE BRAWNY HUMANS 192 00:11:52,799 --> 00:11:56,868 WITH JUST ONE PERSON AT THE CONTROLS. 193 00:11:56,869 --> 00:12:00,338 TO MAKE IT, THEY START WITH A VERTICAL CASE FOR THE WEIGHT. 194 00:12:00,339 --> 00:12:02,373 A HIGH-PRECISION PLASMA TORCH 195 00:12:02,374 --> 00:12:04,709 CUTS STEEL INTO A RECTANGULAR SHAPE 196 00:12:04,710 --> 00:12:07,146 AND MAKES HOLES FOR COMPONENTS. 197 00:12:08,480 --> 00:12:12,550 THEY INSERT THE RECTANGLE INTO A BREAK-PRESS REPEATEDLY 198 00:12:12,551 --> 00:12:14,886 TO BEND IT INTO A THREE-SIDED PART. 199 00:12:14,887 --> 00:12:17,021 THE PROFILE INCLUDES FLANGES 200 00:12:17,022 --> 00:12:20,560 FOR WELDING IT TO THE BACK WALL OF THE CASE. 201 00:12:22,494 --> 00:12:24,496 HE FITS THE PART TO THE BACK WALL 202 00:12:24,497 --> 00:12:28,401 AND WELDS THEM TOGETHER, COMPLETING THE POST DRIVER CASE. 203 00:12:32,305 --> 00:12:35,307 AN EMPLOYEE BUILDS THE POST DRIVER WEIGHT 204 00:12:35,308 --> 00:12:37,411 WORKING WITHIN A WELD FIXTURE. 205 00:12:39,177 --> 00:12:43,416 IT'S A BOX-SHAPED WEIGHT, AND HE WELDS IT AT THE SEAMS. 206 00:12:45,318 --> 00:12:47,486 HE TAPS THE CORNERS BETWEEN THE WELDS 207 00:12:47,487 --> 00:12:50,290 TO MAINTAIN A TIGHT CONFIGURATION. 208 00:12:51,458 --> 00:12:55,493 THIS 300-POUND WEIGHT CAN LATER BE FILLED WITH STEEL SHOT 209 00:12:55,494 --> 00:12:59,564 TO MAKE IT EVEN HEAVIER FOR GREATER IMPACT. 210 00:12:59,565 --> 00:13:02,834 THE NEXT WORKER ASSEMBLES YELLOW STEEL JAWS TO A HUB 211 00:13:02,835 --> 00:13:04,937 TO PRODUCE THE GRAPPLE. 212 00:13:04,938 --> 00:13:07,872 THIS IS THE PART THAT GRIPS THE FENCE POST 213 00:13:07,873 --> 00:13:09,843 AND RAISES IT INTO POSITION. 214 00:13:12,478 --> 00:13:14,945 HE STICKS A DANGER LABEL ONTO THE HUB 215 00:13:14,946 --> 00:13:18,719 TO WARN PEOPLE TO STAY CLEAR OF THESE POWERFUL JAWS. 216 00:13:20,420 --> 00:13:22,755 HE ATTACHES A HYDRAULIC CYLINDER, 217 00:13:22,756 --> 00:13:25,993 WHICH WILL MAKE THE JAWS OPEN AND CLOSE. 218 00:13:27,493 --> 00:13:30,796 HE CONNECTS THE CYLINDER TO THE GRAPPLE JAW. 219 00:13:33,465 --> 00:13:35,299 NEXT, THEY MOVE ON TO THE METAL PLATE 220 00:13:35,300 --> 00:13:38,270 THAT WILL BE USED TO MOUNT THE POST DRIVER TO A VEHICLE, 221 00:13:38,271 --> 00:13:41,073 LIKE A SKID-STEER LOADER. 222 00:13:41,074 --> 00:13:43,107 IT INCLUDES A HYDRAULIC MECHANISM 223 00:13:43,108 --> 00:13:45,878 FOR TILTING THE FENCE POST LEFT OR RIGHT. 224 00:13:49,516 --> 00:13:52,617 THE EMPLOYEE INSTALLS A CONTROL VALVE NEXT TO THE CYLINDER 225 00:13:52,618 --> 00:13:56,088 AND LINKS THE TWO WITH HOSES. 226 00:13:56,089 --> 00:13:57,522 HE'LL ALSO CONNECT THE GRAPPLE 227 00:13:57,523 --> 00:14:00,092 AND WEIGHT HYDRAULICS TO THIS VALVE. 228 00:14:07,800 --> 00:14:11,069 BACK TO THE POST DRIVER CASE NOW -- IT'S BEEN PAINTED, 229 00:14:11,070 --> 00:14:13,704 AND THEY'RE READY TO INSTALL THE HYDRAULIC MOTOR. 230 00:14:13,705 --> 00:14:16,308 THE WORKER CONNECTS IT TO THE SPROCKETS AND CHAINS 231 00:14:16,309 --> 00:14:18,544 THAT WILL LIFT THE WEIGHT. 232 00:14:18,545 --> 00:14:20,346 HE PINS THE SPROCKETS INTO PLACE 233 00:14:20,347 --> 00:14:24,250 AND INSTALLS TENSIONING RODS ON EITHER SIDE. 234 00:14:26,886 --> 00:14:30,421 NEXT, A COVER PLATE PROTECTS THE SPROCKETS. 235 00:14:30,422 --> 00:14:33,392 THE TENSIONING RODS PROTRUDE THROUGH IT. 236 00:14:34,526 --> 00:14:38,295 HE SLIDES SPRINGS ONTO THOSE TENSIONING RODS 237 00:14:38,296 --> 00:14:41,435 AND COMPRESSES THE SPRINGS TO MAINTAIN THE TENSION. 238 00:14:44,470 --> 00:14:48,341 HE NOW ATTACHES THE GRAPPLE TO THE POST DRIVER CASE. 239 00:14:50,676 --> 00:14:53,346 HE LOCKS IT INTO PLACE WITH A LONG PIN. 240 00:14:58,318 --> 00:15:01,553 HE LINKS THE GRAPPLE HYDRAULICS TO THE CONTROL VALVE. 241 00:15:01,554 --> 00:15:03,822 AND IT'S READY TO GRAB BIG FENCE POSTS 242 00:15:03,823 --> 00:15:06,159 AND HOLD ON TIGHT. 243 00:15:09,528 --> 00:15:14,565 THEY ATTACH THE METAL MOUNTING PLATE TO THE POST DRIVER CASE. 244 00:15:14,566 --> 00:15:17,235 THE WORK TABLE TILTS BACK TO MOVE THE POST DRIVER 245 00:15:17,236 --> 00:15:19,506 INTO AN UPRIGHT POSITION. 246 00:15:21,540 --> 00:15:22,973 WITH THE HELP OF A CRANE, 247 00:15:22,974 --> 00:15:25,777 THE NEXT WORKER MOVES THE WEIGHT INTO POSITION 248 00:15:25,778 --> 00:15:28,180 AND LOWERS IT INTO THE CASE. 249 00:15:35,789 --> 00:15:37,557 HE SLIDES A PIN INTO THE TOP END 250 00:15:37,558 --> 00:15:39,290 TO KEEP THE WEIGHT FROM FALLING OUT 251 00:15:39,291 --> 00:15:41,862 WHEN THE POST DRIVER IS ON AN ANGLE. 252 00:15:47,098 --> 00:15:48,699 ONE DAY IN THE MAKING, 253 00:15:48,700 --> 00:15:53,139 THIS HYDRAULIC POST DRIVER IS READY FOR YEARS OF HEAVY LABOR, 254 00:15:53,140 --> 00:15:58,378 TAKING OVER FOR HUMANS SO THEY DON'T HAVE TO MOVE A MUSCLE. 255 00:16:10,000 --> 00:16:11,900 Narrator: A BIPLANE IS A VINTAGE-STYLE AIRCRAFT 256 00:16:11,901 --> 00:16:15,036 WITH TWO PAIRS OF WINGS SITTING ONE ABOVE THE OTHER. 257 00:16:15,037 --> 00:16:18,307 THE TOP WINGS ARE TYPICALLY RAISED ABOVE THE FUSELAGE 258 00:16:18,308 --> 00:16:21,576 WITH VERTICAL STRUTS BRACING THEM TO THE BOTTOM WINGS. 259 00:16:21,577 --> 00:16:24,480 DATING BACK TO THE EARLIEST DAYS OF AVIATION, 260 00:16:24,481 --> 00:16:28,250 THEY'RE STILL POPULAR FOR PERFORMING AEROBATICS. 261 00:16:28,251 --> 00:16:31,719 A BIPLANE'S LOWER WINGS HAVE AILERONS, 262 00:16:31,720 --> 00:16:35,122 WHICH BANK THE AIRPLANE TO THE RIGHT OR LEFT. 263 00:16:35,123 --> 00:16:36,391 ON THE PLANE'S TAIL, 264 00:16:36,392 --> 00:16:39,594 ELEVATORS PITCH THE PLANE'S NOSE UP OR DOWN 265 00:16:39,595 --> 00:16:42,397 WHILE A RUDDER STEERS IT LEFT OR RIGHT. 266 00:16:42,398 --> 00:16:45,766 A PROPELLER PROVIDES THE PROPULSION. 267 00:16:45,767 --> 00:16:48,904 THE PLANE HAS FOUR WINGS. 268 00:16:48,905 --> 00:16:51,106 EACH WING HAS TWO SPARS, 269 00:16:51,107 --> 00:16:53,241 WOODEN BEAMS AT THE FRONT AND REAR, 270 00:16:53,242 --> 00:16:55,276 WHICH FORM THE PERIMETER STRUCTURE. 271 00:16:55,277 --> 00:17:00,115 A CRAFTSMAN SKILLFULLY FASHIONS THESE SPARS OUT OF SITKA SPRUCE. 272 00:17:00,116 --> 00:17:03,751 THIS WOOD IS EXCEEDINGLY LIGHT, YET EXCEPTIONALLY STRONG, 273 00:17:03,752 --> 00:17:05,620 MAKING IT ONE OF ONLY A FEW WOODS 274 00:17:05,621 --> 00:17:09,825 APPROVED FOR STRUCTURAL USE IN AIRPLANES. 275 00:17:09,826 --> 00:17:12,228 AFTER SAWING THE WOOD TO THE SPAR'S SHAPE, 276 00:17:12,229 --> 00:17:15,230 HE MOUNTS ATTACHMENT PLATES MADE OF SITKA SPRUCE 277 00:17:15,231 --> 00:17:17,164 AND MAHOGANY PLYWOOD. 278 00:17:17,165 --> 00:17:18,733 THESE ARE THE END STRUTS, 279 00:17:18,734 --> 00:17:21,136 STEEL VERTICAL BARS WHICH WILL CONNECT THE UPPER 280 00:17:21,137 --> 00:17:23,372 AND LOWER WINGS. 281 00:17:23,373 --> 00:17:26,674 HE FINISHES THE SPAR BY REFINING ITS CONTOUR, 282 00:17:26,675 --> 00:17:31,480 FIRST WITH A HAND PLANE, THEN AN ELECTRIC PLANE. 283 00:17:31,481 --> 00:17:33,682 USING STRIPS OF SITKA SPRUCE, 284 00:17:33,683 --> 00:17:37,653 HE CONSTRUCTS 15 STRUCTURAL RIBS FOR EACH WING. 285 00:17:37,654 --> 00:17:39,655 HE BEGINS WITH LONG STRIPS, 286 00:17:39,656 --> 00:17:43,591 WHICH HAVE BEEN SOAKING IN WATER FOR A WEEK TO MAKE THEM PLIABLE. 287 00:17:43,592 --> 00:17:46,360 HE INSERTS ONE END INTO A CURVED FIXTURE 288 00:17:46,361 --> 00:17:49,263 AND LEAVES THE STRIPS TO DRY. 289 00:17:49,264 --> 00:17:51,767 WHEN HE REMOVES THEM A COUPLE OF DAYS LATER, 290 00:17:51,768 --> 00:17:54,336 THEY HAVE A PERMANENT AERODYNAMIC CURVE. 291 00:17:54,337 --> 00:17:56,405 HE GLUES TWO CURVED STRIPS TOGETHER 292 00:17:56,406 --> 00:17:58,339 TO FORM THE PERIMETER OF ONE RIB. 293 00:17:58,340 --> 00:18:03,677 IN BETWEEN, HE GLUES SHORT DIAGONAL STRIPS CALLED TRUSSES. 294 00:18:03,678 --> 00:18:06,615 HE REINFORCES BOTH SIDES OF EACH INTERSECTION 295 00:18:06,616 --> 00:18:10,485 WITH A RECTANGULAR PIECE CALLED A GUSSET. 296 00:18:10,486 --> 00:18:12,854 AN ASSEMBLER MOUNTS THE 15 RIBS CROSSWISE 297 00:18:12,855 --> 00:18:15,357 ON THE FRONT AND REAR WING SPARS, 298 00:18:15,358 --> 00:18:20,228 THEN INSTALLS THREE ALUMINUM TUBES CALLED COMPRESSION RIBS. 299 00:18:20,229 --> 00:18:22,931 THESE ABSORB AIR LOAD HITTING THE SPARS, 300 00:18:22,932 --> 00:18:26,335 KEEPING THE WOODEN RIBS FROM FLEXING UNDER PRESSURE. 301 00:18:26,336 --> 00:18:28,470 THE CRAFTSMAN CONNECTS THE COMPRESSION RIBS 302 00:18:28,471 --> 00:18:30,874 WITH CRISS-CROSSING METAL RODS. 303 00:18:32,541 --> 00:18:37,545 AFTER APPLYING MORE GLUE TO CRITICAL AREAS, 304 00:18:37,546 --> 00:18:39,181 HE NAILS AN ALUMINUM TRIM 305 00:18:39,182 --> 00:18:42,751 OVER THE FRONT SPAR AND NOSE OF THE RIBS. 306 00:18:42,752 --> 00:18:45,153 THIS IS CALLED THE LEADING EDGE. 307 00:18:45,154 --> 00:18:48,557 IT'S THE FIRST PART OF THE WING TO HIT THE WIND, 308 00:18:48,558 --> 00:18:50,694 SO IT TAKES THE BRUNT OF THE AIR LOAD. 309 00:18:52,529 --> 00:18:56,664 FINALLY, HE LACES REINFORCEMENT TAPE THROUGH THE RIBS 310 00:18:56,665 --> 00:18:59,100 IN AN X PATTERN. 311 00:18:59,101 --> 00:19:02,737 THE COMPLETED STRUCTURE NOW MOVES TO THE COVERING DEPARTMENT 312 00:19:02,738 --> 00:19:04,207 WHERE TECHNICIANS DRAPE IT 313 00:19:04,208 --> 00:19:07,175 IN HEAT SHRINKABLE POLYESTER FABRIC. 314 00:19:07,176 --> 00:19:10,812 THEY CUT THE FABRIC TO SIZE, GLUE IT TO THE WING PERIMETER, 315 00:19:10,813 --> 00:19:12,414 AND HEAT THE SURFACE WITH AN IRON 316 00:19:12,415 --> 00:19:15,116 TO SHRINK THE FABRIC UNTIL IT'S TAUT. 317 00:19:15,117 --> 00:19:19,053 THEN, THEY STITCH OVER THE GLUED AREAS WITH POLYESTER CORD. 318 00:19:19,054 --> 00:19:21,222 THEY BRUSH ON A CHEMICAL WHICH SEALS THE PORES 319 00:19:21,223 --> 00:19:22,857 OF THE FABRIC. 320 00:19:22,858 --> 00:19:25,726 THIS PRIMES THE SURFACE TO RECEIVE A SPRAY COAT 321 00:19:25,727 --> 00:19:27,362 OF POLYURETHANE PAINT, 322 00:19:27,363 --> 00:19:30,934 WHICH IS A SPECIAL FORMULATION DESIGNED FOR AIRCRAFT BODIES. 323 00:19:33,368 --> 00:19:35,904 TECHNICIANS CONSTRUCT THE FUSELAGE FRAME 324 00:19:35,905 --> 00:19:39,473 OUT OF HIGH-STRENGTH STEEL ALLOY TUBES. 325 00:19:39,474 --> 00:19:43,078 THEY USE AN ELECTRIC TORCH TO SLIGHTLY MELT ADJOINING PIECES 326 00:19:43,079 --> 00:19:45,814 SO THEY FUSE TO EACH OTHER. 327 00:19:45,815 --> 00:19:48,817 BECAUSE THERE'S NO FILLER METAL BONDING THE PIECES, 328 00:19:48,818 --> 00:19:51,621 THE WELDS DON'T ADD ANY WEIGHT TO THE STRUCTURE. 329 00:19:54,389 --> 00:19:55,924 AFTER PAINTING THE FRAME, 330 00:19:55,925 --> 00:19:59,895 TECHNICIANS INSTALL ALUMINUM FLOOR PANELS AND BULKHEADS. 331 00:19:59,896 --> 00:20:02,263 IN THE TAIL, THEY ADD LIGHTER WEIGHT BULKHEADS 332 00:20:02,264 --> 00:20:06,534 MADE OF MAHOGANY PLYWOOD AND SITKA SPRUCE. 333 00:20:06,535 --> 00:20:08,203 THEN IT'S TIME TO BOLT THE ENGINE 334 00:20:08,204 --> 00:20:10,840 TO THE FRONT OF THE FUSELAGE FRAME. 335 00:20:16,646 --> 00:20:18,613 THE ENGINE DRIVES A PROPELLER 336 00:20:18,614 --> 00:20:22,418 MADE OF EITHER WOOD, ALUMINUM, OR A COMPOSITE MATERIAL. 337 00:20:22,419 --> 00:20:26,154 PAINTED ALUMINUM BODY PANELS COVER THE FRAME. 338 00:20:26,155 --> 00:20:27,856 TECHNICIANS INSTALL THE FUEL TANK 339 00:20:27,857 --> 00:20:31,159 BETWEEN THE FRONT COCKPIT AND THE ENGINE. 340 00:20:31,160 --> 00:20:34,796 THEN THEY BOLT THE WINGS TO THE FUSELAGE. 341 00:20:34,797 --> 00:20:37,299 VERTICAL STEEL STRUTS CONNECT AND REINFORCE 342 00:20:37,300 --> 00:20:39,134 THE TWO LEVELS OF WINGS 343 00:20:39,135 --> 00:20:42,071 BOLTING TO THOSE ATTACHMENT PLATES ON THE WING SPARS. 344 00:20:44,040 --> 00:20:47,609 NEXT, TECHNICIANS MOUNT THE PAINTED ALUMINUM AILERONS, 345 00:20:47,610 --> 00:20:49,844 THE TAIL, WITH ITS ELEVATORS AND RUDDER 346 00:20:49,845 --> 00:20:52,381 MADE OF PAINTED FABRIC OVER WELDED STEEL, 347 00:20:52,382 --> 00:20:54,348 AND THEN THE ENGINE COVER. 348 00:20:54,349 --> 00:20:56,684 THEY INSTALL A WINDSCREEN 349 00:20:56,685 --> 00:20:59,087 AND INSTRUMENT PANEL FOR EACH COCKPIT. 350 00:20:59,088 --> 00:21:02,790 THE FRONT SCREEN CAN BE REPLACED WITH A COCKPIT COVER 351 00:21:02,791 --> 00:21:06,695 TO KEEP THE PILOTS WARM WHEN FLYING IN COLD WEATHER. 352 00:21:14,271 --> 00:21:17,004 IF YOU HAVE ANY COMMENTS ABOUT THE SHOW, 353 00:21:17,005 --> 00:21:19,473 OR IF YOU'D LIKE TO SUGGEST TOPICS FOR FUTURE SHOWS, 354 00:21:19,474 --> 00:21:22,378 DROP US A LINE AT... 28740

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