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Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated: 1 00:00:01,610 --> 00:00:04,190 In today's impossible engineering. 2 00:00:04,990 --> 00:00:08,109 This is one of the largest regeneration projects in Europe. 3 00:00:08,490 --> 00:00:13,910 Engineers take on one of London's most iconic landmarks. No one has ever tried 4 00:00:13,910 --> 00:00:17,010 to put any kind of lift like this within a chimney. 5 00:00:17,610 --> 00:00:19,570 Attempting an epic transformation. 6 00:00:19,910 --> 00:00:22,370 It is a seemingly impossible task. 7 00:00:22,990 --> 00:00:25,730 Using groundbreaking innovations from the past. 8 00:00:26,050 --> 00:00:27,050 It's 900. 9 00:00:27,280 --> 00:00:31,840 40 degrees in here. The Rockefeller Center, the Chrysler Building, Madison 10 00:00:31,840 --> 00:00:36,580 Square Garden, even the Empire State Building all included beams made here. 11 00:00:37,580 --> 00:00:41,040 That made the impossible possible. 12 00:00:51,180 --> 00:00:52,460 London, England. 13 00:00:55,180 --> 00:01:00,630 At the heart of this. sprawling metropolis, lies one of its most 14 00:01:00,630 --> 00:01:01,630 buildings, 15 00:01:03,170 --> 00:01:05,330 Battersea Power Station. 16 00:01:08,250 --> 00:01:13,810 Nearly 100 years old, in its prime, it supplied electricity to a fifth of homes 17 00:01:13,810 --> 00:01:15,090 and businesses in the capital. 18 00:01:17,730 --> 00:01:22,890 But for more than three decades, this once great cathedral of power had stood 19 00:01:22,890 --> 00:01:23,890 derelict. 20 00:01:25,360 --> 00:01:31,040 Battersea Power Station is a really important, iconic building, partly 21 00:01:31,040 --> 00:01:36,120 of the scale and size of it, but also its location right in the centre of 22 00:01:36,120 --> 00:01:37,860 and on the bank of the River Thames. 23 00:01:39,720 --> 00:01:45,220 But now this legendary building is about to be reinvented, and Sarah Banham is 24 00:01:45,220 --> 00:01:47,500 part of the team facing the daunting task. 25 00:01:48,260 --> 00:01:51,400 I think Battersea Power Station is quite unique. 26 00:01:51,870 --> 00:01:55,910 It's in a lot of films, music. It's instantly recognizable. 27 00:01:56,270 --> 00:01:59,550 But it has been called the Everest of real estate. 28 00:01:59,870 --> 00:02:04,410 It wouldn't have stayed empty for over 30 years if it had been a simple 29 00:02:04,410 --> 00:02:05,410 solution. 30 00:02:08,850 --> 00:02:15,050 The plan is to radically transform this immense 260 ,000 square foot building on 31 00:02:15,050 --> 00:02:16,370 the banks of the River Thames. 32 00:02:18,530 --> 00:02:21,230 On the inside, the old boiler house. 33 00:02:21,450 --> 00:02:26,150 which is large enough to hold four jumbo jets, will become six floors of office 34 00:02:26,150 --> 00:02:29,110 space, plus apartments and an event menu. 35 00:02:30,590 --> 00:02:35,330 On either side of it, the two mammoth turbine halls will be transformed into 36 00:02:35,330 --> 00:02:36,330 retail space. 37 00:02:37,030 --> 00:02:42,150 Next, the two former switch houses are to be converted into over 200 38 00:02:42,150 --> 00:02:43,150 apartments. 39 00:02:44,970 --> 00:02:48,470 Finally, the building's four iconic chimneys will be rebuilt. 40 00:02:48,830 --> 00:02:53,030 and inside one, a cutting -edge glass elevator will be installed, allowing 41 00:02:53,030 --> 00:02:55,950 visitors to enjoy breathtaking views across the capital. 42 00:03:01,410 --> 00:03:06,290 Today, work is nearing completion on the ambitious billion -dollar project 43 00:03:06,290 --> 00:03:12,710 to turn this powerhouse of the past 44 00:03:12,710 --> 00:03:15,750 into a cutting -edge centerpiece of the city. 45 00:03:18,640 --> 00:03:22,120 I think it's the biggest project that I have worked on and certainly one of the 46 00:03:22,120 --> 00:03:23,160 most challenging for me. 47 00:03:24,940 --> 00:03:28,380 There isn't just one building that's being built here. There are effectively 48 00:03:28,380 --> 00:03:31,600 eight all rolled up into one massive project. 49 00:03:34,980 --> 00:03:38,720 On -site project manager Nacho O 'Leary has his hands full. 50 00:03:39,500 --> 00:03:43,700 So we're now approaching the east elevation of the power station. This is 51 00:03:43,700 --> 00:03:44,700 East Annex Wall. 52 00:03:44,800 --> 00:03:47,360 What you can see above us is all the new resident departments. 53 00:03:47,820 --> 00:03:50,580 And this is the new glazing that we're putting in for the shop front that will 54 00:03:50,580 --> 00:03:51,780 be facing the phase one. 55 00:03:52,680 --> 00:03:55,220 The size of the project is astronomical. 56 00:03:55,780 --> 00:03:59,240 This is where the residents will be entering into, coming in through the 57 00:03:59,240 --> 00:04:03,320 landscaping from the side, using the lift, and then going up to their 58 00:04:03,320 --> 00:04:04,320 above. 59 00:04:05,420 --> 00:04:10,400 More than 2 ,500 workers must excavate the equivalent of 60 Olympic swimming 60 00:04:10,400 --> 00:04:11,480 pools worth of earth. 61 00:04:14,240 --> 00:04:20,700 install over 25 ,000 tons of steel structure, and replace 1 .75 62 00:04:20,700 --> 00:04:21,820 million bricks. 63 00:04:22,840 --> 00:04:26,240 The redevelopment of Battersea Power Station is one of the largest projects 64 00:04:26,240 --> 00:04:27,240 going on in Europe. 65 00:04:27,580 --> 00:04:31,780 It's significantly complex in terms of the volume of work that we're 66 00:04:31,780 --> 00:04:36,420 and the number of man hours that we're working to, but also retaining the 67 00:04:36,420 --> 00:04:40,060 existing building and respecting that is a very challenging piece of work. 68 00:04:40,410 --> 00:04:43,790 Many people have tried and failed to redevelop the battery power station. 69 00:04:47,090 --> 00:04:51,930 I've been on here since 2013, right at the very beginning, so I know how 70 00:04:51,930 --> 00:04:56,210 it is. It is seen as a very impossible project for the undertaking, especially 71 00:04:56,210 --> 00:04:57,470 for those that aren't involved. 72 00:04:59,170 --> 00:05:04,610 To repurpose this 20th century icon, the team is facing many extreme engineering 73 00:05:04,610 --> 00:05:05,610 challenges. 74 00:05:08,490 --> 00:05:12,890 How do you keep one of the world's largest brick buildings standing when 75 00:05:12,890 --> 00:05:14,170 slowly turning to dust? 76 00:05:14,850 --> 00:05:18,950 The replacement of the 1 .75 million brick is quite daunting. 77 00:05:20,070 --> 00:05:23,710 And ensure that it doesn't simply collapse when you start repairs. 78 00:05:24,670 --> 00:05:27,450 This isn't just the biggest project that I've ever had to deal with. It's the 79 00:05:27,450 --> 00:05:28,450 most complicated. 80 00:05:29,390 --> 00:05:33,810 How do you thread a new underground railway through one of the world's 81 00:05:33,810 --> 00:05:35,210 subterranean environments? 82 00:05:36,720 --> 00:05:40,680 This is one of the biggest challenges that London Underground has had for 30 83 00:05:40,680 --> 00:05:41,680 years. 84 00:05:42,060 --> 00:05:46,680 Finally, how do you transform a chimney into a world -class tourist attraction? 85 00:05:48,220 --> 00:05:52,900 It has never been done anywhere before, certainly not at this scale, or even 86 00:05:52,900 --> 00:05:54,320 attempted within a chimney like this. 87 00:05:56,700 --> 00:06:01,540 The power station's four distinctive chimneys are an iconic part of the 88 00:06:01,540 --> 00:06:04,620 skyline, but they're in a precarious state. 89 00:06:06,210 --> 00:06:09,170 Nacho O 'Leary is responsible for finding a solution. 90 00:06:11,130 --> 00:06:14,930 The chimneys at Batsi Power Station are the iconic part of the building that 91 00:06:14,930 --> 00:06:16,150 people remember the most. 92 00:06:16,730 --> 00:06:21,110 When I first arrived, we had large lumps of the chimneys falling down from 93 00:06:21,110 --> 00:06:25,510 height at 107 meters high all the way down to ground level of where we are 94 00:06:26,330 --> 00:06:30,510 So because the chimneys were in such a bad condition, there was nothing further 95 00:06:30,510 --> 00:06:32,330 we could do than to take them down. 96 00:06:33,390 --> 00:06:37,110 Piece by piece, the historic structures were carefully removed. 97 00:06:37,530 --> 00:06:41,290 We employed a specialist steeplejack to undertake the work because the works are 98 00:06:41,290 --> 00:06:42,310 happening at such height. 99 00:06:43,030 --> 00:06:47,930 In their place, four identical chimneys, built from steel and reinforced 100 00:06:47,930 --> 00:06:49,830 concrete, start to take shape. 101 00:06:51,250 --> 00:06:55,550 And to ensure they're indistinguishable from the originals, engineers have 102 00:06:55,550 --> 00:06:58,710 replicated the construction method used in the 1930s. 103 00:07:00,510 --> 00:07:06,110 Instead of using a pump, 25 ,000 wheelbarrows full of concrete are taken 104 00:07:06,110 --> 00:07:10,510 160 feet in an elevator and poured into circular mold. 105 00:07:11,930 --> 00:07:15,250 So once the concrete's set, we jump the shuttering. 106 00:07:16,570 --> 00:07:21,030 And where that jump occurs, you can see where the horizontal lines are every 107 00:07:21,030 --> 00:07:22,030 four foot. 108 00:07:23,230 --> 00:07:28,650 Then nearly 400 gallons of protective paint ensures they'll last the next 100 109 00:07:28,650 --> 00:07:29,650 years. 110 00:07:30,990 --> 00:07:34,690 A friend of mine asked why we hadn't replaced the chimneys. He hadn't 111 00:07:34,690 --> 00:07:38,670 that all four of them had been taken down and had gone back up and were 112 00:07:38,670 --> 00:07:40,590 effectively the same as they were originally. 113 00:07:41,790 --> 00:07:46,550 With the chimneys complete, engineers can now attempt the most ambitious part 114 00:07:46,550 --> 00:07:47,550 the project. 115 00:07:48,410 --> 00:07:53,270 The chimney lift is a really large passenger lift with an entirely glazed 116 00:07:53,590 --> 00:07:57,590 The public will be able to come in and get an incredible view across London 117 00:07:57,590 --> 00:08:00,330 the top of the most iconic chimneys in the world. 118 00:08:02,410 --> 00:08:06,170 For engineer Adrian Forge, it's unknown territory. 119 00:08:06,690 --> 00:08:12,110 As far as we know, no one has ever tried to put any kind of lift like this 120 00:08:12,110 --> 00:08:13,110 within a chimney. 121 00:08:13,570 --> 00:08:18,150 It's the chimney's unusual cylindrical shape that makes building an elevator 122 00:08:18,150 --> 00:08:20,350 inside the shaft especially difficult. 123 00:08:20,940 --> 00:08:25,340 So normally a lift shaft is completely straight, but you'll see the chimney 124 00:08:25,340 --> 00:08:30,100 tapers. It's wider at the bottom than it is up at the top, and that's not normal 125 00:08:30,100 --> 00:08:34,059 for a lift shaft. You don't want your lift rails being anything other than 126 00:08:34,059 --> 00:08:37,539 completely plumb and straight, because otherwise you have problems with ride 127 00:08:37,539 --> 00:08:38,539 quality. 128 00:08:39,039 --> 00:08:43,380 But the biggest challenge for engineers is how to pull the elevator to the top. 129 00:08:46,000 --> 00:08:50,660 Because we're trying to give people a view from the top of the chimney, we 130 00:08:50,660 --> 00:08:53,720 have any of our equipment at the top getting in the way of the view. 131 00:08:54,760 --> 00:08:58,560 A large motor at the top could also damage the chimney structure. 132 00:08:59,860 --> 00:09:02,620 The chimneys are designed to be chimneys. 133 00:09:02,960 --> 00:09:05,680 We are putting a lift inside it which is heavy. 134 00:09:05,940 --> 00:09:07,820 The machines that operate it are heavy. 135 00:09:08,360 --> 00:09:13,020 And what we can't do in this lift shaft is put all the weight, all the machinery 136 00:09:13,020 --> 00:09:14,020 at the top. 137 00:09:14,300 --> 00:09:17,100 because we know that the chimneys won't be able to cope with that. 138 00:09:19,740 --> 00:09:22,140 It's a formidable problem to solve. 139 00:09:22,800 --> 00:09:28,520 It has engineering challenges about every aspect of it, so it has certainly 140 00:09:28,520 --> 00:09:30,640 given me sleepless nights. 141 00:09:32,180 --> 00:09:37,520 To find another way of pulling this elevator to the top, engineers need to 142 00:09:37,520 --> 00:09:39,140 to history's great pioneers. 143 00:09:44,240 --> 00:09:49,080 To convert Battersea Power Station's iconic chimneys into one of the best 144 00:09:49,080 --> 00:09:52,740 in London, engineers are turning to their predecessors. 145 00:09:53,400 --> 00:09:58,360 Could the structural difficulties of adding an elevator to a restored chimney 146 00:09:58,360 --> 00:10:00,360 overcome with guidance from the past? 147 00:10:01,080 --> 00:10:06,100 Elevator manufacturer executive Patrick Hess is discovering the secrets behind 148 00:10:06,100 --> 00:10:09,840 an engineering masterpiece located high in the Swiss mountains. 149 00:10:16,170 --> 00:10:21,550 The Bürgenstock Mountain is famous for its unparalleled views and it's been 150 00:10:21,550 --> 00:10:24,870 popular holiday location since 1872. 151 00:10:25,790 --> 00:10:30,510 So one hotel, the Bürgenstock Hotel, wanted to provide something unique to 152 00:10:30,510 --> 00:10:33,690 guests. They wanted to provide a few from the summit. 153 00:10:35,710 --> 00:10:37,810 And this was the result. 154 00:10:40,350 --> 00:10:42,470 This is the Hometschwand lift. 155 00:10:45,520 --> 00:10:52,300 The top is 3 ,700 feet above sea level, making it the tallest 156 00:10:52,300 --> 00:10:54,020 outdoor elevator in Europe. 157 00:10:57,100 --> 00:11:01,140 But building an elevator on the side of a mountain presents a monumental 158 00:11:01,140 --> 00:11:02,140 challenge. 159 00:11:03,620 --> 00:11:07,820 At the time, all elevators have the machinery at the top. 160 00:11:08,140 --> 00:11:12,620 But putting a heavy machine on top of a tall elevator shaft would make the 161 00:11:12,620 --> 00:11:14,140 structure too unstable. 162 00:11:14,670 --> 00:11:18,310 Who would be the engineer brave enough to tackle such a challenge? 163 00:11:21,170 --> 00:11:23,810 Carl Lolle was a German bridge engineer. 164 00:11:24,230 --> 00:11:29,330 But in 1905, he built one of the most astonishing elevators in the world. 165 00:11:32,190 --> 00:11:33,530 What a structure. 166 00:11:33,970 --> 00:11:39,890 In the 1900s, a truly remarkable undertaking and a huge engineering 167 00:11:40,650 --> 00:11:43,370 The elevator shaft is a truss design. 168 00:11:43,840 --> 00:11:46,780 influenced by Lole's railroad bridge background. 169 00:11:47,260 --> 00:11:52,720 To attach the shaft to the mountain, no scaffolding could be brought here. So 170 00:11:52,720 --> 00:11:59,380 builders had to uptail like acrobats on rope in order to drill holes to make 171 00:11:59,380 --> 00:12:01,260 anchor points for the steel structure. 172 00:12:02,420 --> 00:12:07,640 Miners from Italy and Austria were brought in with additional expertise 173 00:12:07,640 --> 00:12:10,220 the rock needed blasting with dynamite. 174 00:12:11,470 --> 00:12:14,870 The shaft needs to be straight to ensure a smooth ride. 175 00:12:15,270 --> 00:12:20,150 We think Lole must have used a plumb line like this. It's a string with a 176 00:12:20,150 --> 00:12:22,850 on the bottom to make the shaft perfectly straight. 177 00:12:27,010 --> 00:12:30,730 Lole's outdoor elevator was a game -changing piece of engineering. 178 00:12:34,050 --> 00:12:38,810 But the real brilliance of the system is in the design of the mechanism. 179 00:12:42,060 --> 00:12:46,520 This is the heavy machine which pulls the car up and down. 180 00:12:47,660 --> 00:12:53,000 After more than 100 years, it's now a new machine, but it's in the same place 181 00:12:53,000 --> 00:12:54,600 Carlole put the machine. 182 00:12:54,920 --> 00:12:58,220 It's on the bottom of the lift and not on the top. 183 00:12:59,780 --> 00:13:05,140 At ground level, a large motor winds steel cables connected to a drum at the 184 00:13:05,140 --> 00:13:06,140 of the shaft. 185 00:13:07,060 --> 00:13:10,960 As the system turns, the car is raised and lowered as required. 186 00:13:12,520 --> 00:13:18,560 This brilliant idea made the shaft more stable and is protecting the machinery 187 00:13:18,560 --> 00:13:20,800 from the difficult weather conditions. 188 00:13:42,490 --> 00:13:43,870 is what it was all for. 189 00:13:45,750 --> 00:13:47,870 Look at this outstanding view. 190 00:13:48,410 --> 00:13:53,630 For the past 120 years, the Hamachfond elevator has provided one of the most 191 00:13:53,630 --> 00:13:55,190 scenic views of the Alps. 192 00:13:55,910 --> 00:13:58,990 Karl Löhle, he was an engineering pioneer. 193 00:13:59,390 --> 00:14:01,670 He has made the impossible possible. 194 00:14:02,010 --> 00:14:06,210 And he has inspired elevator engineers around the world. 195 00:14:19,180 --> 00:14:25,400 At the Battersea Power Station in London, engineer Adrian Forge and the 196 00:14:25,400 --> 00:14:28,860 have taken Lole's strategy to jaw -dropping new heights. 197 00:14:29,760 --> 00:14:32,680 So we can just get ourselves into the lift shaft now. 198 00:14:33,360 --> 00:14:37,880 Lift shafts are normally very protected spaces. Not many people get to go 199 00:14:37,880 --> 00:14:38,880 inside. 200 00:14:41,180 --> 00:14:44,440 So we're right at the bottom of the chimney now. 201 00:14:45,340 --> 00:14:47,320 So the machine is... 202 00:14:47,820 --> 00:14:53,340 I would say the biggest lift motor you can buy. It weighs just over seven tons. 203 00:14:53,800 --> 00:14:57,000 It produces 23 ,000 newton meters of torque. 204 00:14:57,340 --> 00:15:02,400 This chimney lift is absolutely enormous, and that's why we need some 205 00:15:02,400 --> 00:15:03,920 equipment to get it moving. 206 00:15:04,680 --> 00:15:09,240 Just like at the Hummich Fund lift, this monster machine is at the base of the 207 00:15:09,240 --> 00:15:11,140 elevator shaft instead of the top. 208 00:15:11,980 --> 00:15:15,140 By keeping all the equipment at the bottom of the chimney, it means there's 209 00:15:15,140 --> 00:15:19,780 nothing up the top that allows us to bring the lift right out of the top of 210 00:15:19,780 --> 00:15:24,020 chimney. It gives people an amazing view across London from the top of the 211 00:15:24,020 --> 00:15:25,020 chimney itself. 212 00:15:27,820 --> 00:15:32,360 The elevator is pulled up by cables attached to a massive steel ring at the 213 00:15:32,360 --> 00:15:33,360 of the chimney. 214 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 215 00:15:38,740 --> 00:15:41,950 counterweight. It's known as an underslung elevator. 216 00:15:44,450 --> 00:15:49,450 But as the chimney gets narrower towards the top, engineers have also had to 217 00:15:49,450 --> 00:15:53,390 devise an innovative way to ensure the rails inside stay straight. 218 00:15:55,849 --> 00:15:58,550 So these are the rails that the lift car is going to run onto. 219 00:15:58,790 --> 00:16:02,830 We know that this chimney isn't completely straight all the way up, so 220 00:16:02,830 --> 00:16:06,390 going to use these brackets, which are adjustable, to make sure that we can 221 00:16:06,390 --> 00:16:10,570 this rail really straight so that we can give a really good ride quality as 222 00:16:10,570 --> 00:16:11,990 people move up to the top of the chimney. 223 00:16:15,230 --> 00:16:19,550 To get people from the ground to the top of the chimney, engineers have designed 224 00:16:19,550 --> 00:16:23,770 a unique glass car with capacity for 30 people. 225 00:16:24,170 --> 00:16:29,250 A ride to the top of the 350 -foot chimney will take just 26 seconds. 226 00:16:30,410 --> 00:16:36,350 The chimneys are iconic, and what we are trying to create here is a truly unique 227 00:16:36,350 --> 00:16:37,350 experience. 228 00:16:38,150 --> 00:16:41,930 I know that I am going to have been part of something incredibly special. 229 00:16:42,850 --> 00:16:48,190 I think we are going to, at the end of this, be looking on this as an 230 00:16:48,190 --> 00:16:49,530 wonderful feat of engineering. 231 00:16:56,369 --> 00:17:00,590 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 Repair and Synchronization by Easy Subtitles Synchronizer 1.0.0.0 53362

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