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In today's impossible engineering.
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This is one of the largest regeneration
projects in Europe.
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00:00:08,490 --> 00:00:13,910
Engineers take on one of London's most
iconic landmarks. No one has ever tried
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to put any kind of lift like this within
a chimney.
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Attempting an epic transformation.
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It is a seemingly impossible task.
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Using groundbreaking innovations from
the past.
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It's 900.
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40 degrees in here. The Rockefeller
Center, the Chrysler Building, Madison
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Square Garden, even the Empire State
Building all included beams made here.
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That made the impossible possible.
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London, England.
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At the heart of this. sprawling
metropolis, lies one of its most
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buildings,
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Battersea Power Station.
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Nearly 100 years old, in its prime, it
supplied electricity to a fifth of homes
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and businesses in the capital.
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But for more than three decades, this
once great cathedral of power had stood
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derelict.
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Battersea Power Station is a really
important, iconic building, partly
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of the scale and size of it, but also
its location right in the centre of
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and on the bank of the River Thames.
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But now this legendary building is about
to be reinvented, and Sarah Banham is
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part of the team facing the daunting
task.
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I think Battersea Power Station is quite
unique.
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It's in a lot of films, music. It's
instantly recognizable.
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But it has been called the Everest of
real estate.
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It wouldn't have stayed empty for over
30 years if it had been a simple
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solution.
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The plan is to radically transform this
immense 260 ,000 square foot building on
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the banks of the River Thames.
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On the inside, the old boiler house.
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which is large enough to hold four jumbo
jets, will become six floors of office
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space, plus apartments and an event
menu.
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On either side of it, the two mammoth
turbine halls will be transformed into
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retail space.
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Next, the two former switch houses are
to be converted into over 200
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apartments.
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Finally, the building's four iconic
chimneys will be rebuilt.
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and inside one, a cutting -edge glass
elevator will be installed, allowing
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visitors to enjoy breathtaking views
across the capital.
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Today, work is nearing completion on the
ambitious billion -dollar project
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to turn this powerhouse of the past
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into a cutting -edge centerpiece of the
city.
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I think it's the biggest project that I
have worked on and certainly one of the
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most challenging for me.
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There isn't just one building that's
being built here. There are effectively
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eight all rolled up into one massive
project.
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On -site project manager Nacho O 'Leary
has his hands full.
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So we're now approaching the east
elevation of the power station. This is
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East Annex Wall.
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What you can see above us is all the new
resident departments.
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And this is the new glazing that we're
putting in for the shop front that will
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be facing the phase one.
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The size of the project is astronomical.
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This is where the residents will be
entering into, coming in through the
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landscaping from the side, using the
lift, and then going up to their
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above.
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More than 2 ,500 workers must excavate
the equivalent of 60 Olympic swimming
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pools worth of earth.
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install over 25 ,000 tons of steel
structure, and replace 1 .75
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million bricks.
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The redevelopment of Battersea Power
Station is one of the largest projects
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going on in Europe.
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It's significantly complex in terms of
the volume of work that we're
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and the number of man hours that we're
working to, but also retaining the
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existing building and respecting that is
a very challenging piece of work.
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Many people have tried and failed to
redevelop the battery power station.
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I've been on here since 2013, right at
the very beginning, so I know how
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it is. It is seen as a very impossible
project for the undertaking, especially
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for those that aren't involved.
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To repurpose this 20th century icon, the
team is facing many extreme engineering
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challenges.
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How do you keep one of the world's
largest brick buildings standing when
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slowly turning to dust?
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The replacement of the 1 .75 million
brick is quite daunting.
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And ensure that it doesn't simply
collapse when you start repairs.
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This isn't just the biggest project that
I've ever had to deal with. It's the
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most complicated.
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How do you thread a new underground
railway through one of the world's
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subterranean environments?
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This is one of the biggest challenges
that London Underground has had for 30
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years.
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Finally, how do you transform a chimney
into a world -class tourist attraction?
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It has never been done anywhere before,
certainly not at this scale, or even
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attempted within a chimney like this.
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The power station's four distinctive
chimneys are an iconic part of the
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skyline, but they're in a precarious
state.
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Nacho O 'Leary is responsible for
finding a solution.
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The chimneys at Batsi Power Station are
the iconic part of the building that
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people remember the most.
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When I first arrived, we had large lumps
of the chimneys falling down from
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height at 107 meters high all the way
down to ground level of where we are
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So because the chimneys were in such a
bad condition, there was nothing further
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we could do than to take them down.
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Piece by piece, the historic structures
were carefully removed.
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We employed a specialist steeplejack to
undertake the work because the works are
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happening at such height.
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In their place, four identical chimneys,
built from steel and reinforced
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concrete, start to take shape.
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And to ensure they're indistinguishable
from the originals, engineers have
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replicated the construction method used
in the 1930s.
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Instead of using a pump, 25 ,000
wheelbarrows full of concrete are taken
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160 feet in an elevator and poured into
circular mold.
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So once the concrete's set, we jump the
shuttering.
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And where that jump occurs, you can see
where the horizontal lines are every
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four foot.
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Then nearly 400 gallons of protective
paint ensures they'll last the next 100
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years.
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A friend of mine asked why we hadn't
replaced the chimneys. He hadn't
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that all four of them had been taken
down and had gone back up and were
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effectively the same as they were
originally.
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With the chimneys complete, engineers
can now attempt the most ambitious part
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the project.
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The chimney lift is a really large
passenger lift with an entirely glazed
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The public will be able to come in and
get an incredible view across London
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the top of the most iconic chimneys in
the world.
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For engineer Adrian Forge, it's unknown
territory.
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As far as we know, no one has ever tried
to put any kind of lift like this
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within a chimney.
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It's the chimney's unusual cylindrical
shape that makes building an elevator
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inside the shaft especially difficult.
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So normally a lift shaft is completely
straight, but you'll see the chimney
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tapers. It's wider at the bottom than it
is up at the top, and that's not normal
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for a lift shaft. You don't want your
lift rails being anything other than
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completely plumb and straight, because
otherwise you have problems with ride
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quality.
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But the biggest challenge for engineers
is how to pull the elevator to the top.
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Because we're trying to give people a
view from the top of the chimney, we
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have any of our equipment at the top
getting in the way of the view.
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A large motor at the top could also
damage the chimney structure.
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The chimneys are designed to be
chimneys.
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We are putting a lift inside it which is
heavy.
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The machines that operate it are heavy.
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And what we can't do in this lift shaft
is put all the weight, all the machinery
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at the top.
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because we know that the chimneys won't
be able to cope with that.
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It's a formidable problem to solve.
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It has engineering challenges about
every aspect of it, so it has certainly
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given me sleepless nights.
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To find another way of pulling this
elevator to the top, engineers need to
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to history's great pioneers.
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To convert Battersea Power Station's
iconic chimneys into one of the best
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in London, engineers are turning to
their predecessors.
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Could the structural difficulties of
adding an elevator to a restored chimney
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overcome with guidance from the past?
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Elevator manufacturer executive Patrick
Hess is discovering the secrets behind
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an engineering masterpiece located high
in the Swiss mountains.
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The Bürgenstock Mountain is famous for
its unparalleled views and it's been
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popular holiday location since 1872.
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So one hotel, the Bürgenstock Hotel,
wanted to provide something unique to
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guests. They wanted to provide a few
from the summit.
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And this was the result.
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This is the Hometschwand lift.
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The top is 3 ,700 feet above sea level,
making it the tallest
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outdoor elevator in Europe.
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But building an elevator on the side of
a mountain presents a monumental
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challenge.
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At the time, all elevators have the
machinery at the top.
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But putting a heavy machine on top of a
tall elevator shaft would make the
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structure too unstable.
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Who would be the engineer brave enough
to tackle such a challenge?
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Carl Lolle was a German bridge engineer.
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But in 1905, he built one of the most
astonishing elevators in the world.
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What a structure.
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In the 1900s, a truly remarkable
undertaking and a huge engineering
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The elevator shaft is a truss design.
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influenced by Lole's railroad bridge
background.
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To attach the shaft to the mountain, no
scaffolding could be brought here. So
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builders had to uptail like acrobats on
rope in order to drill holes to make
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anchor points for the steel structure.
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Miners from Italy and Austria were
brought in with additional expertise
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the rock needed blasting with dynamite.
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The shaft needs to be straight to ensure
a smooth ride.
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We think Lole must have used a plumb
line like this. It's a string with a
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on the bottom to make the shaft
perfectly straight.
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Lole's outdoor elevator was a game
-changing piece of engineering.
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But the real brilliance of the system is
in the design of the mechanism.
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This is the heavy machine which pulls
the car up and down.
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After more than 100 years, it's now a
new machine, but it's in the same place
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Carlole put the machine.
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It's on the bottom of the lift and not
on the top.
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At ground level, a large motor winds
steel cables connected to a drum at the
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of the shaft.
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As the system turns, the car is raised
and lowered as required.
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This brilliant idea made the shaft more
stable and is protecting the machinery
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from the difficult weather conditions.
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is what it was all for.
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Look at this outstanding view.
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For the past 120 years, the Hamachfond
elevator has provided one of the most
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scenic views of the Alps.
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Karl Löhle, he was an engineering
pioneer.
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He has made the impossible possible.
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And he has inspired elevator engineers
around the world.
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At the Battersea Power Station in
London, engineer Adrian Forge and the
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have taken Lole's strategy to jaw
-dropping new heights.
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So we can just get ourselves into the
lift shaft now.
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Lift shafts are normally very protected
spaces. Not many people get to go
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inside.
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So we're right at the bottom of the
chimney now.
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So the machine is...
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I would say the biggest lift motor you
can buy. It weighs just over seven tons.
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It produces 23 ,000 newton meters of
torque.
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This chimney lift is absolutely
enormous, and that's why we need some
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equipment to get it moving.
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00:15:04,680 --> 00:15:09,240
Just like at the Hummich Fund lift, this
monster machine is at the base of the
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elevator shaft instead of the top.
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By keeping all the equipment at the
bottom of the chimney, it means there's
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nothing up the top that allows us to
bring the lift right out of the top of
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chimney. It gives people an amazing view
across London from the top of the
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chimney itself.
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The elevator is pulled up by cables
attached to a massive steel ring at the
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of the chimney.
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00:15:34,220 --> 00:15:38,740
Cables run down to the motor at the
bottom, back up to the top, and down to
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counterweight. It's known as an
underslung elevator.
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00:15:44,450 --> 00:15:49,450
But as the chimney gets narrower towards
the top, engineers have also had to
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devise an innovative way to ensure the
rails inside stay straight.
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00:15:55,849 --> 00:15:58,550
So these are the rails that the lift car
is going to run onto.
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00:15:58,790 --> 00:16:02,830
We know that this chimney isn't
completely straight all the way up, so
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00:16:02,830 --> 00:16:06,390
going to use these brackets, which are
adjustable, to make sure that we can
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00:16:06,390 --> 00:16:10,570
this rail really straight so that we can
give a really good ride quality as
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00:16:10,570 --> 00:16:11,990
people move up to the top of the
chimney.
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To get people from the ground to the top
of the chimney, engineers have designed
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a unique glass car with capacity for 30
people.
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A ride to the top of the 350 -foot
chimney will take just 26 seconds.
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The chimneys are iconic, and what we are
trying to create here is a truly unique
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experience.
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I know that I am going to have been part
of something incredibly special.
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I think we are going to, at the end of
this, be looking on this as an
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wonderful feat of engineering.
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Engineers may have found a way to retain
the power station's iconic chimneys,
232
00:17:00,790 --> 00:17:03,510
but now they face a more fundamental
problem.
233
00:17:04,450 --> 00:17:07,510
The power station when we arrived on
site was sterile.
234
00:17:07,710 --> 00:17:12,190
The largest space between the four
chimneys was entirely empty.
235
00:17:12,470 --> 00:17:14,069
We needed to start putting in floors.
236
00:17:14,650 --> 00:17:19,250
To solve it, the team will have to turn
to the great innovators of the past.
237
00:17:19,450 --> 00:17:24,490
To construct a super tall tower,
engineers would need super strong steel
238
00:17:29,130 --> 00:17:33,410
In London, the Battersea Power Station
redevelopment is one of the most
239
00:17:33,410 --> 00:17:36,190
astonishing construction projects on the
planet.
240
00:17:40,270 --> 00:17:46,530
This enormous industrial icon covers an
area over 260 ,000 square feet,
241
00:17:46,870 --> 00:17:49,490
equivalent to 96 tennis courts.
242
00:17:50,830 --> 00:17:54,950
Its steel frame consists of 8 ,000
individual sections.
243
00:17:55,440 --> 00:18:00,740
Around that, six million bricks formed
the walls of the structure, making it
244
00:18:00,740 --> 00:18:03,000
of the largest brick buildings in the
world.
245
00:18:04,920 --> 00:18:08,900
But having had its roof and floors
removed over 30 years ago,
246
00:18:09,640 --> 00:18:14,140
engineers now face the task of finding a
way to divide this empty shell of a
247
00:18:14,140 --> 00:18:18,000
building into homes, offices, retail,
and event space.
248
00:18:19,980 --> 00:18:24,200
It's the biggest engineering challenge
Michael Brooks has ever faced.
249
00:18:25,290 --> 00:18:29,450
So, the power station when we arrived on
site was derelict.
250
00:18:29,870 --> 00:18:31,510
Lots of the floors were missing.
251
00:18:31,970 --> 00:18:36,990
The largest space between the four
chimneys was entirely emptied.
252
00:18:37,710 --> 00:18:41,430
150 meters by 150 meters by 60 meters
tall.
253
00:18:41,690 --> 00:18:45,450
The volume of space that needed filling.
We needed to start putting in floors.
254
00:18:48,770 --> 00:18:51,970
The team plans to install 14 new floors.
255
00:18:52,460 --> 00:18:56,760
The problem they face is that, unlike
the office and residential spaces at the
256
00:18:56,760 --> 00:19:01,440
top of the building, which can be
supported with columns, the retail and
257
00:19:01,440 --> 00:19:06,680
space below must remain open, forcing
engineers to find another solution.
258
00:19:09,040 --> 00:19:14,460
We've got a retail mall, we've got
office space, we've got an event space,
259
00:19:14,460 --> 00:19:18,360
all of these different uses have
different structural needs.
260
00:19:18,750 --> 00:19:22,850
We can have columns within an office
space, but we don't want to have columns
261
00:19:22,850 --> 00:19:23,829
an event space.
262
00:19:23,830 --> 00:19:25,070
How do we overcome that challenge?
263
00:19:26,210 --> 00:19:28,690
It is a seemingly impossible task.
264
00:19:29,850 --> 00:19:35,130
To achieve strength on such an enormous
scale, engineers will need inspiration
265
00:19:35,130 --> 00:19:37,130
from history's great pioneers.
266
00:19:47,590 --> 00:19:53,790
Urban planner Cara Michelle is in
Bethlehem, Pennsylvania, uncovering a
267
00:19:53,790 --> 00:19:57,670
revelation that is behind New York's
biggest skyscrapers.
268
00:19:58,110 --> 00:20:02,730
In the 19th century, Manhattan's
population was booming.
269
00:20:03,090 --> 00:20:06,810
And the only way to accommodate everyone
was to build higher.
270
00:20:07,710 --> 00:20:11,590
By that time, buildings were already
starting to get taller, but they were
271
00:20:11,590 --> 00:20:13,770
typically limited to about 20 stories.
272
00:20:14,590 --> 00:20:19,570
To construct a super tall tower,
engineers would need super strong steel
273
00:20:20,430 --> 00:20:23,370
Luckily, one man was working on a
solution.
274
00:20:26,710 --> 00:20:32,490
In the late 1890s, English engineer
Henry Gray patented a new method for
275
00:20:32,490 --> 00:20:36,790
creating steel beams that were much
stronger than those that currently
276
00:20:40,150 --> 00:20:44,130
It was an innovation that would change
skylines around the world.
277
00:20:44,540 --> 00:20:46,040
And it all started here.
278
00:20:50,860 --> 00:20:56,700
This is the former Bethlehem Steelworks,
known as the place that built America.
279
00:20:58,620 --> 00:21:03,700
The Rockefeller Center, the Chrysler
Building, Madison Square Garden, even
280
00:21:03,700 --> 00:21:06,980
Empire State Building all included beams
made here.
281
00:21:11,180 --> 00:21:13,040
Bethlehem Steel owners took a risk.
282
00:21:13,340 --> 00:21:18,240
Henry Gray steel mills were new and
different, and almost no one else was
283
00:21:18,240 --> 00:21:22,640
them. But they bought the patent anyway,
and they began manufacturing.
284
00:21:28,780 --> 00:21:33,200
Gray steel rolling mill could make beams
stronger than had ever been achieved
285
00:21:33,200 --> 00:21:34,200
before.
286
00:21:34,940 --> 00:21:37,820
So what made these beams so resistant to
bending?
287
00:21:40,380 --> 00:21:45,760
When a beam has weight on it, The top is
in compression, pushing the steel, and
288
00:21:45,760 --> 00:21:48,260
the bottom is in tension, pulling the
steel.
289
00:21:49,840 --> 00:21:54,880
By changing the shape of the beam, more
steel is at the top and the bottom where
290
00:21:54,880 --> 00:21:55,880
it's needed most.
291
00:22:01,180 --> 00:22:02,740
I've got two beams here.
292
00:22:02,940 --> 00:22:04,380
They're both the same weight.
293
00:22:04,640 --> 00:22:07,540
The only difference between the two of
them is their shape.
294
00:22:08,040 --> 00:22:12,300
This one is a straight beam, while this
one is a wide -flanged beam.
295
00:22:13,080 --> 00:22:17,620
So we're going to put these two beams to
the test to see which one is more
296
00:22:17,620 --> 00:22:18,620
resistant to bending.
297
00:22:20,360 --> 00:22:22,060
First, the straight beam.
298
00:22:23,480 --> 00:22:28,940
Already, I'm hardly putting any weight
on it, and I can feel it bending
299
00:22:28,940 --> 00:22:31,420
underneath me. It is so flexible.
300
00:22:31,920 --> 00:22:36,620
I don't necessarily know if this is what
I would want to have holding up my
301
00:22:36,620 --> 00:22:37,620
floor.
302
00:22:38,240 --> 00:22:40,400
Now, the wide -flanged beam.
303
00:22:40,940 --> 00:22:43,580
Already I can really feel the
difference.
304
00:22:44,520 --> 00:22:48,500
And I don't feel that same amount of
give underneath me.
305
00:22:48,780 --> 00:22:50,580
Actually, this is pretty impressive.
306
00:22:54,120 --> 00:22:56,500
Bethlehem Steel's gamble had paid off.
307
00:22:56,860 --> 00:23:02,980
By the 1920s, its beams were part of 80
% of New York's iconic skyscrapers.
308
00:23:04,750 --> 00:23:09,590
Henry Gray was able to produce the wide
flange beam better than anyone else had
309
00:23:09,590 --> 00:23:10,590
achieved.
310
00:23:10,790 --> 00:23:15,210
His bend -resistant beams made it
possible to build tall, multi -story
311
00:23:15,210 --> 00:23:18,690
buildings, changing skylines all across
America.
312
00:23:29,090 --> 00:23:31,290
Back at Battersea Power Station.
313
00:23:32,050 --> 00:23:36,830
Engineers are using bend -resistant
steel beams to make 14 new floors.
314
00:23:38,350 --> 00:23:43,190
And one in particular needs to be able
to take the weight of eight new stories
315
00:23:43,190 --> 00:23:44,190
by itself.
316
00:23:50,250 --> 00:23:56,170
This gigantic beam is almost 90 feet
long and weighs a whopping 68 ton.
317
00:23:58,000 --> 00:24:01,640
It's one of the largest pieces of steel
ever made in the UK.
318
00:24:03,040 --> 00:24:07,560
Gray's historic wide -flanged beam made
this remarkable piece of engineering a
319
00:24:07,560 --> 00:24:10,440
key component in Battersea Power
Station's redesign.
320
00:24:11,600 --> 00:24:16,540
But now the team is faced with another
massive challenge, installation.
321
00:24:17,200 --> 00:24:22,840
We had to run tests with lorries with
brooms and ladders out the back just to
322
00:24:22,840 --> 00:24:25,880
make sure that we could actually
navigate the length of the beam through
323
00:24:25,880 --> 00:24:26,880
site.
324
00:24:28,330 --> 00:24:33,250
In the restoration and renovation of
London's historic Battersea Power
325
00:24:33,510 --> 00:24:37,590
engineer Michael Brooks was charged with
one of the most difficult parts of the
326
00:24:37,590 --> 00:24:43,150
entire process, delivering and
installing a record -breaking wide
327
00:24:43,150 --> 00:24:45,510
that will support 14 new floors.
328
00:24:45,830 --> 00:24:51,530
It was picked up by the second -largest
crane in Europe with a capacity just
329
00:24:51,530 --> 00:24:55,010
enough to pick up this beam and install
it in place.
330
00:24:55,420 --> 00:24:59,600
It was a very significant and obvious
milestone for us.
331
00:25:02,040 --> 00:25:04,980
So here is the 62 -ton beam.
332
00:25:05,300 --> 00:25:07,880
It is a supersized I -beam.
333
00:25:08,280 --> 00:25:12,860
We have huge amounts of area of steel at
the top and at the bottom, and not so
334
00:25:12,860 --> 00:25:15,300
much in the middle, and that gives us a
high bending resistance.
335
00:25:17,800 --> 00:25:22,240
Located on the building's fifth floor,
the gigantic beam supports the weight of
336
00:25:22,240 --> 00:25:23,540
the eight stories above.
337
00:25:24,030 --> 00:25:26,590
leaving the event space below column
free.
338
00:25:27,930 --> 00:25:33,410
Then, by adding two vast steel trees,
engineers are able to create floors for
339
00:25:33,410 --> 00:25:35,930
offices above, maximizing the space.
340
00:25:39,390 --> 00:25:43,090
These are the structural transfer trees.
341
00:25:45,020 --> 00:25:49,640
We have one column underneath, what we
call the trunk, and sprouting out of it
342
00:25:49,640 --> 00:25:53,960
are four branches that then divide again
further up into eight branches, and it
343
00:25:53,960 --> 00:25:58,040
travels all the way up to the underside
of the level five, which is where we
344
00:25:58,040 --> 00:25:59,140
have the office space above.
345
00:25:59,380 --> 00:26:01,220
Each of these trees...
346
00:26:01,500 --> 00:26:03,240
supports six office columns.
347
00:26:03,620 --> 00:26:08,560
And by taking six columns above and
pulling all of the load down into one
348
00:26:08,560 --> 00:26:13,380
central megacolumn below, what we've
been able to do is create this grand
349
00:26:13,380 --> 00:26:17,740
as people walk into the retail mall and
yet allow us to maximize the space for
350
00:26:17,740 --> 00:26:18,740
the office above.
351
00:26:20,520 --> 00:26:23,420
The power station redevelopment is well
underway.
352
00:26:24,140 --> 00:26:28,740
But with no direct underground rail link
to the site, the team still needs to
353
00:26:28,740 --> 00:26:30,500
find a way for people to get here.
354
00:26:30,860 --> 00:26:33,980
So with the regeneration of the area,
there's going to be around 20 ,000 new
355
00:26:33,980 --> 00:26:38,200
jobs created, which will mean that we
need a transport hub to bring people in
356
00:26:38,200 --> 00:26:39,079
and out.
357
00:26:39,080 --> 00:26:43,660
For Jonathan Cooper, it will require
some of the most complex engineering on
358
00:26:43,660 --> 00:26:48,500
project. We are going to build a new
underground tube station at Battersea
359
00:26:48,500 --> 00:26:52,640
Station. This is one of the biggest
challenges that London Underground has
360
00:26:52,640 --> 00:26:53,640
for 30 years.
361
00:26:56,090 --> 00:27:00,570
Engineers have formed an ambitious plan
to dig a pair of tunnels almost two
362
00:27:00,570 --> 00:27:04,330
miles long, connecting the site with the
existing northern line.
363
00:27:07,210 --> 00:27:11,450
And where the old and new sections of
tunnel meet, junctions will need to be
364
00:27:11,450 --> 00:27:14,170
created to accommodate the additional
section of track.
365
00:27:17,630 --> 00:27:22,070
We've got to connect the existing
northern line, which is around 100 years
366
00:27:22,270 --> 00:27:26,280
into the new tunnel. This is really
difficult because... The tunnel that
367
00:27:26,280 --> 00:27:29,800
connecting into has to remain
operational at all times.
368
00:27:32,760 --> 00:27:38,480
The process starts with two 700 -ton
tunnel boring machines being lowered 85
369
00:27:38,480 --> 00:27:39,500
feet underground.
370
00:27:41,420 --> 00:27:42,540
Watch the step here.
371
00:27:43,080 --> 00:27:46,280
So this is where the tunnel boring
machines were brought down in 20 -metre
372
00:27:46,280 --> 00:27:48,920
sections. They were put together and
pushed into the launch tunnels.
373
00:27:49,760 --> 00:27:53,800
Moving at two inches a minute, they
grind through the London clay.
374
00:27:55,490 --> 00:27:59,950
Behind the boring machine, the freshly
excavated tunnel is sprayed with
375
00:27:59,950 --> 00:28:01,830
to create a reinforced lining.
376
00:28:02,770 --> 00:28:04,530
It is very dark down here.
377
00:28:06,890 --> 00:28:11,290
Roughly halfway along the route,
engineers face the most precarious part
378
00:28:11,290 --> 00:28:12,290
process,
379
00:28:12,790 --> 00:28:16,530
tunneling just six feet below the
existing Victoria Line.
380
00:28:17,760 --> 00:28:21,840
While we were tunneling through this
area, the operational service continued
381
00:28:21,840 --> 00:28:24,860
whole time, and no one even knew that we
were tunneling under here.
382
00:28:25,440 --> 00:28:28,320
We're so close to the Victoria Line
train here that you can actually hear
383
00:28:28,320 --> 00:28:30,300
trains going above us when they pass.
384
00:28:32,760 --> 00:28:33,760
Right there.
385
00:28:38,100 --> 00:28:42,700
After tunneling for nine months, the
team eventually reaches the site of the
386
00:28:42,700 --> 00:28:43,960
existing Northern Line.
387
00:28:46,440 --> 00:28:48,900
But there's one final problem to
overcome.
388
00:28:49,880 --> 00:28:54,920
In order to tie the old line to the new
one, engineers must connect the two with
389
00:28:54,920 --> 00:28:55,920
a junction.
390
00:28:55,980 --> 00:29:01,020
To do this, they dig a larger tunnel
around the old one, revealing the
391
00:29:01,020 --> 00:29:04,080
cast iron tube that dates back over 100
years.
392
00:29:05,140 --> 00:29:08,700
Next, a prototype machine lines the new
larger tunnel.
393
00:29:08,980 --> 00:29:13,020
Meanwhile, inside the existing tube,
trains continue to run.
394
00:29:14,540 --> 00:29:19,220
Then, with the services halted for the
weekend, the old section of cast -iron
395
00:29:19,220 --> 00:29:22,700
tunnel is removed and the two
underground lines are connected.
396
00:29:27,680 --> 00:29:30,140
This is where the new tunnel joins with
the old tunnel.
397
00:29:31,440 --> 00:29:36,600
It's really awesome to see a train
running in the underground because it's
398
00:29:36,600 --> 00:29:38,860
restricted area, and normally you can't
see this.
399
00:29:40,240 --> 00:29:42,900
This has been the biggest project I've
ever been involved in.
400
00:29:43,950 --> 00:29:46,050
I'm really excited about seeing it
complete.
401
00:29:52,750 --> 00:29:57,230
Back on site, the team still faces one
of the biggest challenges of the
402
00:29:57,230 --> 00:29:58,970
Battersea Power Station project.
403
00:29:59,530 --> 00:30:03,150
We think we need an order of 1 .75
million for it.
404
00:30:03,710 --> 00:30:09,190
To tackle this 21st century problem,
engineers will need to look to the past.
405
00:30:09,550 --> 00:30:13,070
You can totally see it's glowing almost
bright white.
406
00:30:18,780 --> 00:30:20,420
In the heart of London,
407
00:30:21,160 --> 00:30:25,620
Battersea Power Station, once an
essential piece of infrastructure that
408
00:30:25,620 --> 00:30:28,620
electricity to the capital, is being
reborn.
409
00:30:31,080 --> 00:30:36,320
After laying derelict for more than 30
years, today engineers are converting
410
00:30:36,320 --> 00:30:39,500
this iconic structure into a brand new
neighborhood.
411
00:30:39,850 --> 00:30:43,250
where future generations will live,
work, and play.
412
00:30:47,750 --> 00:30:53,990
So far, the structure's four famous
chimneys have been rebuilt, with one of
413
00:30:53,990 --> 00:30:58,830
transformed into a unique glass elevator
that will offer visitors stunning views
414
00:30:58,830 --> 00:30:59,830
across the city.
415
00:31:01,010 --> 00:31:05,830
27 ,000 tons of steel has helped to
construct 14 new floors.
416
00:31:07,370 --> 00:31:11,890
And the London Underground has been
extended by nearly two miles, giving
417
00:31:11,890 --> 00:31:13,310
Battersea its own station.
418
00:31:16,250 --> 00:31:18,770
But on site... We've just got a ramp
here.
419
00:31:19,030 --> 00:31:20,030
Be careful here.
420
00:31:20,810 --> 00:31:25,990
Project manager Nacho O 'Leary still has
one final, crucial problem to crack.
421
00:31:26,610 --> 00:31:29,710
Battersea Power Station is one of the
biggest brick buildings in Europe.
422
00:31:30,140 --> 00:31:34,060
Over a number of years, the bricks have
been exposed to the elements of water
423
00:31:34,060 --> 00:31:35,060
and also to wind.
424
00:31:35,240 --> 00:31:39,380
A number of the bricks that you can see
have already defaced, just purely down
425
00:31:39,380 --> 00:31:42,840
to the lack of maintenance that happened
for about 30 years whilst the building
426
00:31:42,840 --> 00:31:43,840
laid open.
427
00:31:44,340 --> 00:31:48,820
In total, over 6 million bricks were
laid by hand when the structure was
428
00:31:48,820 --> 00:31:51,240
originally constructed back in 1929.
429
00:31:52,060 --> 00:31:56,980
But more than nine decades later, this
aging brickwork is presenting a problem
430
00:31:56,980 --> 00:31:58,260
for Nacho and the team.
431
00:31:58,590 --> 00:32:02,130
Where we've had the water ingress come
through, some of the damage has meant
432
00:32:02,130 --> 00:32:04,870
that a lot of the bricks are actually
unstable.
433
00:32:05,150 --> 00:32:06,430
This is a prime example.
434
00:32:06,710 --> 00:32:10,110
It's got a lot of mortar around it, and
this crumbles away quite easily.
435
00:32:10,650 --> 00:32:15,330
The mortar is actually not holding the
bricks in at heights of 56, 58 meters
436
00:32:15,330 --> 00:32:19,850
high. We're having to take out the
unsafe structure to make sure that
437
00:32:19,850 --> 00:32:20,990
damage to the builders below.
438
00:32:22,430 --> 00:32:26,410
With the crumbling, weathered bricks and
mortar in the process of being removed,
439
00:32:26,650 --> 00:32:31,410
Engineers will need to replace them with
new materials. But this presents a huge
440
00:32:31,410 --> 00:32:36,130
problem. We think we need in the order
of 1 .75 million bricks just for
441
00:32:36,130 --> 00:32:39,890
replacement. So that's not including the
new walls that have gone up. That's
442
00:32:39,890 --> 00:32:44,130
just replacing bricks that have been
exposed over time to the elements.
443
00:32:45,690 --> 00:32:51,530
But making 1 .75 million new bricks that
match the original is a huge challenge.
444
00:32:53,270 --> 00:32:57,030
Engineers will need to look back to the
19th century for the solution.
445
00:33:05,830 --> 00:33:10,710
Archaeologist Kathy Newland is in
Gloucester, England, exploring how an
446
00:33:10,710 --> 00:33:14,730
brick production technique could help
make millions of bricks for Battersea.
447
00:33:15,610 --> 00:33:19,390
Bricks are absolutely essential in the
Industrial Revolution.
448
00:33:20,040 --> 00:33:23,000
You've got all these infrastructure
projects. You've got canals, you've got
449
00:33:23,000 --> 00:33:24,660
bridges, you've got housing, you've got
factories.
450
00:33:24,920 --> 00:33:27,660
All those things absolutely depend on
bricks.
451
00:33:28,540 --> 00:33:33,160
The problem was that brickwork simply
couldn't keep up with the enormous
452
00:33:34,220 --> 00:33:36,040
Making bricks is actually quite a fine
art.
453
00:33:36,560 --> 00:33:40,280
You've got to heat it up really slowly,
really gently, hold it at firing
454
00:33:40,280 --> 00:33:44,540
temperature for a perfect amount of
time, and then cool it just as gently.
455
00:33:44,860 --> 00:33:47,400
If you do it right, you get something
like this.
456
00:33:47,620 --> 00:33:48,640
If you do it wrong...
457
00:33:50,160 --> 00:33:51,300
You're going to get this.
458
00:33:51,900 --> 00:33:57,920
Boldy, cracky, not fired properly, not
structurally sound, absolutely no good
459
00:33:57,920 --> 00:33:58,920
for engineering.
460
00:33:59,500 --> 00:34:01,660
And it's a process you just can't rush.
461
00:34:06,580 --> 00:34:12,480
Fortunately, in 1858, German engineer
Friedrich Hoffmann invented a system
462
00:34:12,480 --> 00:34:13,960
would revolutionize production.
463
00:34:17,100 --> 00:34:21,800
Rather than using separate ovens to fire
bricks, Hoffman's innovation used
464
00:34:21,800 --> 00:34:26,500
multiple interconnected chambers that
allowed heat to pass between them,
465
00:34:26,500 --> 00:34:28,900
a vast number of bricks at the same
time.
466
00:34:32,179 --> 00:34:37,940
At the Northcott Brickworks, their
gigantic Hoffman kiln measures 130 feet
467
00:34:38,159 --> 00:34:43,699
64 feet long, and is capable of holding
up to 264 ,000 bricks.
468
00:34:45,130 --> 00:34:48,870
If we look in the ceiling, we can see
feed holes. This is where the fuel comes
469
00:34:48,870 --> 00:34:53,949
in. Right at the beginning, in the
1850s, this would all have been coal
470
00:34:53,949 --> 00:34:54,949
down around the bricks.
471
00:34:55,690 --> 00:34:59,290
And if we look down in the corner, down
here, there's a second set of holes
472
00:34:59,290 --> 00:35:02,710
really low down. These are called the
trace holes. And they are kind of the
473
00:35:02,710 --> 00:35:04,630
genius bit of Hoffman's invention.
474
00:35:05,010 --> 00:35:09,870
They allow you to use the hot gases from
the combustion chambers, draw it
475
00:35:09,870 --> 00:35:13,130
through all of your other chambers to
preheat those bricks.
476
00:35:13,740 --> 00:35:17,520
And that's why Hoffman design is so
cutting edge. It saves you time, because
477
00:35:17,520 --> 00:35:20,580
they're already preheated, and it saves
you money that you're not spending on
478
00:35:20,580 --> 00:35:21,580
coal.
479
00:35:24,680 --> 00:35:29,600
When one set of bricks is being fired,
the chambers near it warm up too.
480
00:35:30,520 --> 00:35:34,480
So when the next chamber is fired, the
bricks are already preheated.
481
00:35:35,680 --> 00:35:40,220
And when bricks are finished, they're
kept warm, allowing them to cool slowly.
482
00:35:51,840 --> 00:35:54,960
That's the first chamber, and that's
being set.
483
00:35:55,280 --> 00:35:59,320
The second chamber here, bricks are all
in there. There's something like 16 ,000
484
00:35:59,320 --> 00:36:00,740
bricks packed into that little space.
485
00:36:00,940 --> 00:36:04,120
And then you brick it off with these
bricks, which is what you call the door.
486
00:36:04,360 --> 00:36:07,720
And then we go down to the third chamber
where the bricks have been sealed.
487
00:36:08,080 --> 00:36:13,220
You've had this sort of clay mixture put
on it to keep all the air out to make a
488
00:36:13,220 --> 00:36:14,220
decent seal.
489
00:36:14,360 --> 00:36:16,940
And then round here is where it gets
really hot.
490
00:36:17,550 --> 00:36:20,110
Now this is all ready to go and it is
being fired.
491
00:36:20,390 --> 00:36:25,230
It's 940 degrees in here and it will be
kept to that temperature for another six
492
00:36:25,230 --> 00:36:26,230
hours.
493
00:36:26,330 --> 00:36:27,930
And it's really throwing out some heat.
494
00:36:29,970 --> 00:36:34,090
Now coming round this corner, this one's
cooling down, making sure those bricks
495
00:36:34,090 --> 00:36:35,210
come out perfectly.
496
00:36:36,730 --> 00:36:41,390
It takes about three days to get from a
freshly fired chamber to cool enough to
497
00:36:41,390 --> 00:36:42,390
deal with.
498
00:36:46,600 --> 00:36:51,300
Having a Hoffman kiln could increase a
factory's production from 2 million
499
00:36:51,300 --> 00:36:54,080
bricks a year to 20 million.
500
00:36:54,920 --> 00:36:59,740
Thanks to Hoffman and his innovative
kiln, enough bricks could finally be
501
00:36:59,740 --> 00:37:02,660
produced to meet the demands of the
Industrial Revolution.
502
00:37:03,240 --> 00:37:08,660
And because of the savings in time and
in fuel, two Hoffman kilns were being
503
00:37:08,660 --> 00:37:10,380
built all over the world.
504
00:37:18,700 --> 00:37:24,040
Hoffman's pioneering kiln proved so
effective and durable, some are still in
505
00:37:24,040 --> 00:37:30,300
today. And Battersea Power Station's
engineers... This kiln is so good that
506
00:37:30,300 --> 00:37:33,840
is as efficient as a modern -day kiln.
507
00:37:34,060 --> 00:37:36,740
...will put one in particular to good
use.
508
00:37:41,180 --> 00:37:46,080
To meet their need for over a million
new bricks, the engineers at Battersea
509
00:37:46,080 --> 00:37:50,470
Power Station... have turned to this
historic Hoffman Kiln at Northcott
510
00:37:50,470 --> 00:37:51,470
Brickworks.
511
00:37:53,010 --> 00:37:58,090
The very same one that the original
bricks for the building were fired in
512
00:37:58,090 --> 00:37:59,290
in 1929.
513
00:38:02,610 --> 00:38:07,310
Overseeing the massive undertaking, Dale
Moss is confident that Friedrich
514
00:38:07,310 --> 00:38:09,090
Hoffman's innovation will deliver.
515
00:38:10,290 --> 00:38:12,950
The Hoffman Kiln is vital.
516
00:38:13,310 --> 00:38:14,510
It gives you variation.
517
00:38:15,320 --> 00:38:20,420
It enables the beauty of the brick to be
achieved.
518
00:38:22,680 --> 00:38:27,720
Unbelievably, most of the 1 .3 million
bricks are being made by hand.
519
00:38:28,040 --> 00:38:32,960
And Dale has an innovative technique to
ensure the new bricks precisely match
520
00:38:32,960 --> 00:38:34,740
their 95 -year -old counterparts.
521
00:38:37,000 --> 00:38:43,470
We've developed our own weathering
antiquing process where... We can age
522
00:38:43,470 --> 00:38:45,770
bricks to match old buildings.
523
00:38:46,750 --> 00:38:53,030
So we weather them by putting them into
water, into weathering fluids for
524
00:38:53,030 --> 00:38:54,030
various times.
525
00:38:54,670 --> 00:38:58,330
The new bricks blend seamlessly with the
originals.
526
00:38:59,510 --> 00:39:05,250
Personally, making the bricks the
Battersea Power Station is my biggest
527
00:39:05,250 --> 00:39:06,250
achievement.
528
00:39:08,090 --> 00:39:09,470
Back on site.
529
00:39:09,720 --> 00:39:14,200
Bricklayers are painstakingly laying new
bricks to carefully match the original
530
00:39:14,200 --> 00:39:15,200
pattern.
531
00:39:17,000 --> 00:39:21,940
There are over seven different types of
brick and 20 different types of mortar.
532
00:39:22,780 --> 00:39:26,480
This mammoth task will take around five
years to complete.
533
00:39:32,140 --> 00:39:36,840
But at the top of the building, project
manager Nacho O 'Leary faces another
534
00:39:36,840 --> 00:39:37,840
problem.
535
00:39:38,710 --> 00:39:44,110
Over 160 feet in the air, here it's too
difficult, dangerous, and time
536
00:39:44,110 --> 00:39:47,430
-consuming for workers to lay individual
bricks by hand.
537
00:39:48,790 --> 00:39:51,050
This is the east wall of the boiler
house.
538
00:39:51,290 --> 00:39:54,210
We've had to replace the bricks that
were originally here.
539
00:39:55,150 --> 00:39:58,810
There's about 750 ,000 bricks in this
facade alone.
540
00:40:02,030 --> 00:40:07,490
So, to speed things up, the team created
giant 13 -foot square brick panels.
541
00:40:07,710 --> 00:40:11,190
that can be lifted into place quickly
and safely by a crane.
542
00:40:13,250 --> 00:40:18,090
By using panels, not only was it easier
for us to install and had less impact on
543
00:40:18,090 --> 00:40:22,470
other works going on, but it was a lot
quicker way for us to actually mount the
544
00:40:22,470 --> 00:40:25,850
volume of bricks we had to the wall to
form the wall itself.
545
00:40:26,650 --> 00:40:31,030
That reduces risk on site, and that's a
massively significant point to flag when
546
00:40:31,030 --> 00:40:32,030
using panels.
547
00:40:40,680 --> 00:40:46,300
This historic power station that stood
derelict for decades
548
00:40:46,300 --> 00:40:52,340
has been transformed.
549
00:40:55,060 --> 00:40:59,780
I'm very proud to save this wonderful
historic building.
550
00:41:02,180 --> 00:41:07,860
Battersea Power Station is without doubt
the most exciting engineering project I
551
00:41:07,860 --> 00:41:08,860
have ever.
552
00:41:08,890 --> 00:41:10,290
been involved in.
553
00:41:11,850 --> 00:41:15,090
It's been a privilege to work on one of
the largest brick buildings in the
554
00:41:15,090 --> 00:41:16,089
world.
555
00:41:16,090 --> 00:41:18,930
And it's a very proud project for me to
be involved with.
556
00:41:19,710 --> 00:41:23,010
The thing that I think we like most
about it is the challenge.
557
00:41:23,870 --> 00:41:26,750
The engineering skill behind it has been
tremendous.
558
00:41:31,670 --> 00:41:33,930
Inspired by the innovators of the past.
559
00:41:35,950 --> 00:41:37,850
By adapting their ideas.
560
00:41:39,530 --> 00:41:41,770
and refining their design.
561
00:41:42,230 --> 00:41:46,510
I'm really excited about the opportunity
to be a part of this project that will
562
00:41:46,510 --> 00:41:49,250
push the boundaries of structural
engineering.
563
00:41:50,650 --> 00:41:56,190
Engineers have breathed new life into
this iconic structure.
564
00:41:56,240 --> 00:42:00,790
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