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Narrator: How did
a team of engineers

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nicknamed the extreme team

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build a futuristic
research station

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in the world's most
extreme climate?

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Man: This is a really
savage environment

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for any building to endure.

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It's just really
harsh out there.

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You've got temperatures
that go as low

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as negative 58 degrees celsius,

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and then you have wind speeds

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that go as high as 160
kilometres per hour.

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Narrator: How does
this stunning visual trick

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make a 3,500-ton
concrete arch levitate?

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Woman: It looks like the wing

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is floating completely
unsupported.

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Narrator: And how did they build

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the world's first
rotating boat lift,

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able to carry 500 tons
of water and two boats

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over 65 feet into the air?

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Woman: All the
falkirk wheel needs

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is the equivalent power
of eight boiling kettles.

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♪

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Narrator: This is the
age of the extraordinary...

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Man: This house
always is on the verge

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of falling down.

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Narrator: Where
ingenious engineers

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have unleashed
unchecked creativity...

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Woman: Everything
in this building

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pushes at the boundaries
of what's possible.

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Narrator: Building structures
so outrageous, they defy logic.

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Woman: The forces on this thing

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look like it should
be torn apart.

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Narrator: Now their
secrets are revealed.

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Discover the incredible
stories of their construction...

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Woman: These are
extraordinary feats of engineering.

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Narrator: To try and understand

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how did they build that?

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Imagine the engineering it takes

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to build an advanced
scientific research centre

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that can cope with
outside temperatures

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of minus 58 degrees
fahrenheit and house 60 people.

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It has to be completely
self-sufficient

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for months on end

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and be able to move locations
quickly when danger strikes.

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Debbie sterling: It's
a brutal environment

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for any building to survive in.

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Narrator: But
that's the building

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the British antarctic
survey needed,

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a mobile research
station that could survive

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in the most hostile place
on earth... Antarctica.

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This ingenious
series of rugged pods

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uses train and space
shuttle technology

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so that top scientists can
study our planet's atmosphere

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all year round.

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But designing something that
could be built on a slab of ice

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10,000 miles from home
was a massive challenge.

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Ellie cosgrave: The
people who were building it

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had to actually use
electrically heated gloves

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to counteract the frostbite.

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Narrator: The crippling cold
was only one of the hurdles

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a dedicated team had to
overcome to pull this off.

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[Crunching]

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Every part had to be
delivered to an ice dock

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that could crack
open at any moment.

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Snowdrifts would Bury
the buildings and equipment

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in the blink of an eye.

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And the summer build
season was so short,

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it would take five
years to complete.

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The result was the extreme
mobile research station

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called halley vi.

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So, how did they build it?

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For the last 65 years,
britain has been pioneering

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the scientific study of
the earth's atmosphere

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in the most extreme
environment on earth.

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Joshua macabuag: This place
has 1.2 meters of snow a year,

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and the snow that
does fall, it never melts.

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Then you have the drifts.

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This is a big wide-open space,
so anything that you put there

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is going to gather
a lot of snow on it.

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Narrator: Despite
the tough conditions,

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the clean air and
low light pollution

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are the reasons why the
British antarctic survey

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has been building
research stations

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in the antarctic since 1956.

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In 1985, its scientists
discovered a huge hole

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in the ozone layer,

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a finding that led to the
global banning of cfcs,

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reversing a
potential catastrophe.

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Named after the great
astronomer Edmond halley,

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the first four halley bases
were simple structures

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that worked for a while,

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but always ended up
buried deep under the ice.

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In 1989, they upped their game,

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building the fifth base
on adjustable stilts.

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Hugh broughton: So,
halley v was quite clever

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because it has
these screw Jacks,

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which meant the building
could be jacked up every year

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@by a meter or
a meter and a half

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to help it escape from
the rising snow level.

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Narrator: So halley v could
move upwards to avoid the snow,

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but there was a bigger
problem it couldn't escape.

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Every year the
ice shelf it's built on

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moves 1,300 feet
closer to the sea.

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Debbie: The halley v's
legs were fixed into the ice,

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and so they had to
throw that design away

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because there was a risk
that the ice could break off

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and the whole thing
could just drift into the sea.

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Narrator: It was time for a new,
better halley research station.

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Architect Hugh broughton
Rose to the challenge

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of designing a station
that could overcome

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the difficulties of being built
and operating in Antarctica.

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From the start, he faced
an unusual set of limitations.

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Hugh: Everything that
needs to be delivered to halley

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first of all gets unloaded
from a ship onto sea ice,

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and the maximum
weight of component

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could be no more than nine tons.

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Then the other challenge
is that this building

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needed to be relocatable
between 15 to 20 kilometres,

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so quite a decent move.

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Narrator: Being able
to move the station

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to avoid being
stranded on an iceberg

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topped the already
formidable design criteria.

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Some radical
thinking was needed.

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Hugh: The first thing we decided

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is that we should come
up with a modular solution,

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so break the requirements of
the British antarctic survey's brief

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down into a series of
interconnected buildings,

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and the reason we did
that is that those buildings

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could be disconnected
and moved more easily

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from one site to another.

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Nehemiah mabry: The modular
construction is really fitting

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for remote
environments like this,

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much likeúthe
international space station,

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where you can put
things together bit by bit

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without having
to dig foundations

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or anything that you
would traditionally see

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in a more reasonable
environment.

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Joshua: The eight pods,
there's two sleeping pods,

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two science pods, two
generator and plant pods,

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one command pod, and
one double height living pod.

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Narrator: Along with a
team of expert engineers,

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the architects
created a blueprint

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for what would be
the most complete,

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extreme environment
accommodation ever built.

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Eight individual
pods would be linked

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through enclosed
gangways, like train carriages,

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to create one integrated
living and working organism.

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To cope with the
constantly rising snow,

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huge hydraulically
adjustable legs would allow it

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to be raised and lowered,

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and each leg would sit on
a massive teflon-coated ski.

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If danger threatened, each
module could be detached

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and moved to a new location,

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where the station
would be reconnected,

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avoiding a catastrophe.

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The modular plan solved
many of the problems

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the extreme
environment presented,

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but there was no getting away

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from the greatest
single challenge

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facing its construction,

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the extremely short
summer building season

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of just 12 weeks between
December and February.

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Hugh: The construction
season in the antarctic

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is unbelievably short.

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Days in January and December,
which might be minus 5,

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suddenly at the end of
February, beginning of march,

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you're working at minus 25,

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and that's pretty hardcore
if you're working outside,

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so then you've got
to leave your site

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for the following 10 months,
until you can come back again.

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Narrator: While the
construction crew could fly in

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on a Russian transport plane,

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all their tools and supplies
had to be delivered by ship.

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The logistics here
were tough enough,

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but it was that short
three-month window

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when external work was possible

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that meant a traditional
approach to construction

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was impossible.

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Hayley loren oakes: The
only really sensible solution

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was to prefabricate
everything in a warm country,

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in this case, South Africa.

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Narrator: To
maximize efficiency,

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the engineers test-built two
complete modules near Cape Town.

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This meant they could
perfect components

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and train the construction team

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before shipping all the parts
4,300 miles to Antarctica.

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Hugh: The buildings were
built as in a kind of kit form,

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and that's because
it's hard to move things

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when the ship arrives
at the edge of the sea ice.

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Narrator: The on-site
build began in 2007.

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Icebreaker ships
had to straighten

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the edge of the ice shelf.

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Once in position, everything
was unloaded at breakneck speed.

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The planning had
been meticulous.

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Hugh: We wanted to be
able to unload components,

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for the components
to be as big as possible

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within that weight
restriction of nine tons,

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and for all the parts to
be able to click together

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as quickly as possible.

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The biggest part that we
made was the steel frame,

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which forms the base
of each of the modules,

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which is basically a whole
series of tubes joined together

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in a three-dimensional
form to maximize strength

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and making it easier
to move from the ship

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to the building site.

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Narrator: For seven days,

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caterpillar tractors
worked nonstop,

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pulling 500 tons of
cargo 7 1/2 miles inland,

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to the still-functioning
halley v base.

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The result was an
extraordinary collection

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of prefabricated components
awaiting assembly on the ice.

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Joshua: Everything was
arranged in a very well-organized,

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very well-labeled line,
four kilometres long.

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Narrator: The plan was to
get each module on its legs

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and with all the key components
fitted before winter arrived,

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which would shut down the
site until the following year.

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The construction crew of 40 men,

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who lived in prefabricated
huts near halley v,

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worked in shifts around
the clock to stay on schedule.

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Hugh: In order to maximize

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the efficiency of the
construction process,

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we approached it in the same
way almost that you would

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an assembly line for making
a car or something like that,

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so we had one crew
doing steel frames,

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another crew building shell.

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Joshua: Given the dangers
of being in the antarctic

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and the limitations on space,

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all of the builders had to be
able to do more than one job.

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Hugh: There would be a team

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installing the primary
building services,

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things like the generators,
the sewage treatment,

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the water production unit,

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and then the service connections
that go between the modules.

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Joshua: These were
definitely no ordinary builders.

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In fact, they were
nicknamed the extreme team.

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Man: Behind me is the
second energy module

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with all the plant and equipment
placed upon the floor deck.

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The obvious ones to point out

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are the big pink tank at
the back, which is fuel,

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and the big grey tank at
the front, which is water.

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Narrator: Every single
unit that could be pre-built

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before arrival had been.

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Man: As you can see, there's
the prefabricated bedrooms,

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plant room, and wc.

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Next stage for this is to have

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00:12:16,431 --> 00:12:18,345
the structural steelwork
erected around it.

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Hugh: The bedrooms had the
beds in, the desks in, the wardrobes.

248
00:12:21,871 --> 00:12:24,308
We didn't go as far as putting
the duvets and the pillows on,

249
00:12:25,396 --> 00:12:26,702
but it was pretty close to that.

250
00:12:28,051 --> 00:12:29,922
Narrator: By the
time the extreme team

251
00:12:29,923 --> 00:12:31,662
had the pod
frames on their legs,

252
00:12:31,663 --> 00:12:34,143
with the key
components fixed inside,

253
00:12:34,144 --> 00:12:35,824
the days were becoming
very cold and short.

254
00:12:36,407 --> 00:12:40,367
It was time to
wrap the structures

255
00:12:40,368 --> 00:12:42,085
and prepare the site for
the bitter winter to come.

256
00:12:42,109 --> 00:12:46,199
They could only hope

257
00:12:46,200 --> 00:12:47,330
the equipment and
materials would survive.

258
00:12:47,331 --> 00:12:48,724
Hugh: So, if you're
going to leave

259
00:12:49,812 --> 00:12:51,291
any of your equipment there,

260
00:12:51,292 --> 00:12:52,858
you need to make sure
that it's durable enough

261
00:12:52,859 --> 00:12:54,419
to withstand the
harsh antarctic winter,

262
00:12:54,817 --> 00:12:57,993
and that was a hard thing to do.

263
00:12:57,994 --> 00:12:59,690
There are materials
which are used

264
00:12:59,691 --> 00:13:01,170
in food cold stores
and things like that,

265
00:13:01,171 --> 00:13:03,130
but they typically
go down to minus 25.

266
00:13:04,087 --> 00:13:06,350
But to say to someone,

267
00:13:08,265 --> 00:13:09,005
"oh, no, your product's actually
going to go down to minus 55,"

268
00:13:09,006 --> 00:13:10,833
that's sort of a
different level.

269
00:13:12,139 --> 00:13:15,315
Narrator: During
testing off-site,

270
00:13:15,316 --> 00:13:17,056
the module cladding
was found to be too brittle.

271
00:13:17,057 --> 00:13:19,059
As a result, no work
was done in the antarctic

272
00:13:20,147 --> 00:13:22,062
the following summer season,

273
00:13:23,715 --> 00:13:25,715
while the materials were
perfected in South Africa.

274
00:13:26,109 --> 00:13:29,764
Finally, 21 months
after wrapping them up,

275
00:13:29,765 --> 00:13:32,594
the extreme team returned,

276
00:13:34,465 --> 00:13:36,162
and the half-built modules
were released from winter's grip.

277
00:13:36,163 --> 00:13:38,600
Man: Ok, so here we
are on the halley vi site,

278
00:13:40,384 --> 00:13:42,822
and these structures are
going to be towed up a ramp,

279
00:13:44,519 --> 00:13:46,584
and the snow height here
is about 20 foot at the back,

280
00:13:46,608 --> 00:13:49,392
so we'll clear it
out, make a ramp,

281
00:13:49,393 --> 00:13:51,393
tow the structures out,
and take them to the south.

282
00:13:51,700 --> 00:13:54,094
Narrator: Cladding
the modules was next.

283
00:13:55,182 --> 00:13:58,706
It was these improved panels

284
00:13:58,707 --> 00:14:00,403
that would give the halley vi
pods their distinctive shape,

285
00:14:00,404 --> 00:14:02,842
a look inspired by a
50-year-old kids' TV series.

286
00:14:06,280 --> 00:14:10,370
Ellie: I can totally
see this in the design,

287
00:14:10,371 --> 00:14:12,211
but apparently the
architects and the engineers

288
00:14:12,242 --> 00:14:15,157
for this project were inspired

289
00:14:15,158 --> 00:14:16,767
by the sixties puppet
show "thunderbirds."

290
00:14:16,768 --> 00:14:18,568
Hugh: I was a massive
fan of the thunderbirds.

291
00:14:19,293 --> 00:14:22,686
I think the influence
is pretty clear,

292
00:14:22,687 --> 00:14:25,167
and thunderbird 2 was coursing
through the design from day one.

293
00:14:25,516 --> 00:14:27,867
Narrator: The
thunderbirds-inspired pods

294
00:14:28,737 --> 00:14:30,478
wouldn't just look good.

295
00:14:32,132 --> 00:14:34,089
Crucially, they would
be the first line of defense

296
00:14:34,090 --> 00:14:36,490
against the harsh weather for
everything and everyone inside.

297
00:14:38,355 --> 00:14:42,271
Hayley: The walls are made
of glass-reinforced polymer,

298
00:14:42,272 --> 00:14:44,072
or grp, and more commonly
known as fibreglass.

299
00:14:45,972 --> 00:14:48,409
It's 75 percent lighter
than the steel equivalent,

300
00:14:50,715 --> 00:14:53,153
and it's super strong,
and it's lightweight,

301
00:14:54,632 --> 00:14:56,286
and it can actually
resist corrosion,

302
00:14:57,809 --> 00:15:00,029
and best of all, it's
a brilliant insulator.

303
00:15:01,813 --> 00:15:05,207
Narrator: Although fibreglass
was known to be tough,

304
00:15:05,208 --> 00:15:07,036
Hugh needed to be
sure it would survive

305
00:15:08,081 --> 00:15:10,082
the antarctic conditions.

306
00:15:10,083 --> 00:15:11,693
Hugh: When we were having

307
00:15:13,129 --> 00:15:14,434
the glass fibre
shell manufactured,

308
00:15:14,435 --> 00:15:16,515
we went through a really
rigorous process of testing.

309
00:15:16,654 --> 00:15:18,700
We subjected it to the effects

310
00:15:20,093 --> 00:15:22,442
of the ice being
blown in the wind,

311
00:15:22,443 --> 00:15:24,163
so we blasted it with
sand to simulate that.

312
00:15:24,967 --> 00:15:26,607
We sprayed water at
the cladding material,

313
00:15:27,317 --> 00:15:30,319
or the building shell material,

314
00:15:30,320 --> 00:15:32,278
and then lowered the
temperature really quickly

315
00:15:32,279 --> 00:15:34,359
to see what happens under
freeze/thaw kind of cycles.

316
00:15:35,847 --> 00:15:38,285
Narrator: The
glass fibre cladding,

317
00:15:39,982 --> 00:15:41,504
backed by 12 inches of
high-performance insulation,

318
00:15:41,505 --> 00:15:44,855
would protect the
researchers from the cold,

319
00:15:44,856 --> 00:15:48,294
but there is another extreme

320
00:15:48,295 --> 00:15:49,382
from which people
here need protection...

321
00:15:49,383 --> 00:15:51,559
The light or lack thereof.

322
00:15:53,300 --> 00:15:55,260
Hugh: We decided that
at the heart of the station,

323
00:15:56,477 --> 00:15:59,131
in the main big
red social module,

324
00:15:59,132 --> 00:16:00,655
it'd be really great
if we could have

325
00:16:02,265 --> 00:16:03,570
a big double-height
space with a big window

326
00:16:03,571 --> 00:16:05,225
because you just
get really nice light

327
00:16:06,313 --> 00:16:08,836
in the antarctic in the summer,

328
00:16:08,837 --> 00:16:09,664
and it would just provide
a really great social focus

329
00:16:09,665 --> 00:16:13,623
for the community.

330
00:16:13,624 --> 00:16:14,451
But of course, the big challenge
you have in the antarctic

331
00:16:14,452 --> 00:16:18,672
is if you create a big window,

332
00:16:18,673 --> 00:16:20,413
then it's also a source of
massive heat loss potentially,

333
00:16:20,414 --> 00:16:23,242
so we, we really searched
high and wide around

334
00:16:23,243 --> 00:16:25,114
and discovered this
incredible material

335
00:16:26,594 --> 00:16:28,234
that was invented by
NASA, called nanogel.

336
00:16:29,640 --> 00:16:31,880
Narrator: Nanogel was used
on the space shuttle nose cone

337
00:16:32,948 --> 00:16:34,828
to protect it from the
extreme heat of re-entry,

338
00:16:36,430 --> 00:16:38,750
but it is equally effective at
protecting from extreme cold

339
00:16:40,608 --> 00:16:43,002
and also happens
to be translucent.

340
00:16:44,655 --> 00:16:46,855
Hugh: Around 50 percent
of light is actually transmitted

341
00:16:47,571 --> 00:16:49,008
through this material,

342
00:16:50,792 --> 00:16:52,097
so we have this big window
at the heart of the station

343
00:16:52,098 --> 00:16:53,795
which allows lots of
good natural light in

344
00:16:55,492 --> 00:16:57,412
without letting lots of
heat out of the building.

345
00:16:57,886 --> 00:17:00,062
Narrator: With 1,300
feet of the ice shelf

346
00:17:01,411 --> 00:17:03,847
flowing out into
the sea every year,

347
00:17:03,848 --> 00:17:05,728
by December 2011, the
third season of the build,

348
00:17:06,895 --> 00:17:09,335
it was time to tow the modules
nine miles inland from halley v

349
00:17:11,595 --> 00:17:14,076
and the ever-approaching edge.

350
00:17:15,556 --> 00:17:16,996
But by now, with
modules fully built,

351
00:17:18,472 --> 00:17:20,632
even the smaller blue pods
weighed as much as 100 tons.

352
00:17:22,128 --> 00:17:24,434
Ellie: The biggest
challenge to getting the pods

353
00:17:26,088 --> 00:17:27,697
to their new home over
the last 15 kilometres

354
00:17:27,698 --> 00:17:29,298
was overcoming
something called stiction.

355
00:17:31,006 --> 00:17:32,549
This is the static friction
that needs to be overcome

356
00:17:32,573 --> 00:17:34,575
to get objects to move.

357
00:17:36,272 --> 00:17:38,012
Narrator: The designers
turned to a very common material

358
00:17:38,013 --> 00:17:41,407
found in almost every kitchen.

359
00:17:41,408 --> 00:17:44,236
Hugh: The skis are made
out of high-grade steel

360
00:17:44,237 --> 00:17:45,757
that's suitable for
a cold environment,

361
00:17:46,761 --> 00:17:48,805
and then they have
a layer of teflon,

362
00:17:48,806 --> 00:17:50,526
which is essentially
fixed to the underside,

363
00:17:50,678 --> 00:17:52,201
to help them to
glide across the ice.

364
00:17:53,681 --> 00:17:56,074
Narrator: The skis
were so effective,

365
00:17:56,075 --> 00:17:58,337
the extreme team
had to make sure

366
00:17:58,338 --> 00:18:00,426
the 100-ton pods
didn't run out of control.

367
00:18:00,427 --> 00:18:02,864
Man: Stage two. Last
night, it was pulled off

368
00:18:04,257 --> 00:18:06,475
the construction
line at this end,

369
00:18:06,476 --> 00:18:07,911
turned round, and a
few tests done on it.

370
00:18:07,912 --> 00:18:09,992
What we're interested in
is how slowly can we tow it,

371
00:18:10,350 --> 00:18:13,352
how easily you can control it,
and how quickly you can stop it

372
00:18:13,353 --> 00:18:14,876
or what the stopping
distances are

373
00:18:16,356 --> 00:18:18,574
because when we
get to the other end,

374
00:18:18,575 --> 00:18:19,749
they will have to be a
certain distance apart.

375
00:18:19,750 --> 00:18:22,709
Narrator: Twice the
size of the blue modules,

376
00:18:22,710 --> 00:18:24,670
the red command module
proved much harder to move.

377
00:18:25,843 --> 00:18:28,237
Man: We're definitely
over 200 tons with it,

378
00:18:29,760 --> 00:18:31,360
so it's out of our
comfort zone slightly,

379
00:18:33,024 --> 00:18:35,723
but a good team on the job.

380
00:18:36,811 --> 00:18:39,073
If anybody can shift it, we can.

381
00:18:39,074 --> 00:18:40,641
Operator: Ok, on the count of 3.

382
00:18:42,512 --> 00:18:44,471
♪

383
00:18:49,824 --> 00:18:52,261
Narrator: Moving
the eight modules

384
00:18:53,306 --> 00:18:55,916
the nine miles took days,

385
00:18:55,917 --> 00:18:58,287
and as each module arrived to
meet its new next-door neighbour,

386
00:18:58,311 --> 00:19:00,835
they were introduced
with a bang.

387
00:19:03,751 --> 00:19:06,883
[Bang]

388
00:19:06,884 --> 00:19:09,165
The connecting gangways
proved to be resilient components.

389
00:19:09,887 --> 00:19:13,455
Ellie: They connected the pods
using a double-layered version

390
00:19:13,456 --> 00:19:14,896
of the kind of
concertina connections

391
00:19:16,329 --> 00:19:18,330
that you see in many
railway carriages.

392
00:19:18,331 --> 00:19:21,507
Hugh: They're insulated
when they're used

393
00:19:21,508 --> 00:19:22,986
in the Scandinavian
countries, so again,

394
00:19:22,987 --> 00:19:24,728
it's normally used
in the rail industry,

395
00:19:26,382 --> 00:19:28,688
but we just transferred
it over to our buildings.

396
00:19:28,689 --> 00:19:30,864
Narrator: Finally, all eight
modules were linked and sealed

397
00:19:30,865 --> 00:19:34,694
from the weather.

398
00:19:34,695 --> 00:19:35,956
The only exterior connection
was a safety gantry,

399
00:19:35,957 --> 00:19:38,438
an intentional
firebreak to protect

400
00:19:39,787 --> 00:19:41,067
one set of modules
from the other

401
00:19:42,398 --> 00:19:44,318
in the event of a
catastrophic fire or explosion.

402
00:19:45,488 --> 00:19:47,969
The last job of the year
was to prepare halley vi

403
00:19:49,100 --> 00:19:51,190
for the next blast of winter.

404
00:19:52,887 --> 00:19:55,497
Hugh: Because the snow
level is constantly rising,

405
00:19:55,498 --> 00:19:56,938
what you do is
that each leg in turn,

406
00:19:58,153 --> 00:19:59,593
you lift it up, using
the hydraulics,

407
00:20:00,416 --> 00:20:02,201
you push snow underneath

408
00:20:04,072 --> 00:20:05,333
to make a platform of around
one to one and a half meters,

409
00:20:05,334 --> 00:20:08,945
and when you've
done all of the legs,

410
00:20:08,946 --> 00:20:10,382
you then use the hydraulics
again to Jack the building up

411
00:20:10,383 --> 00:20:12,994
so it's sitting on
these snow platforms

412
00:20:14,430 --> 00:20:15,870
well above the
surrounding ice level,

413
00:20:16,563 --> 00:20:18,521
and then when it snows

414
00:20:20,088 --> 00:20:21,654
and the wind blows snow
around over the winter

415
00:20:21,655 --> 00:20:23,415
and the level rises by
one and a half meters,

416
00:20:25,006 --> 00:20:26,853
it brings the whole thing
kind of up to a level again.

417
00:20:26,877 --> 00:20:29,010
Narrator: In February 2012,

418
00:20:30,403 --> 00:20:31,883
over five years
after the build began,

419
00:20:32,448 --> 00:20:34,581
halley vi came into service

420
00:20:36,278 --> 00:20:38,318
as the British antarctic
survey's new research base.

421
00:20:38,585 --> 00:20:41,022
Its 60 occupants had
never known such luxury.

422
00:20:42,545 --> 00:20:44,852
Nehemiah: If you're
going to do research

423
00:20:46,593 --> 00:20:47,463
and you're going to live in
one of the coldest places,

424
00:20:47,464 --> 00:20:50,117
if not the coldest
place on earth,

425
00:20:50,118 --> 00:20:52,641
then the least you can do

426
00:20:52,642 --> 00:20:54,077
is have a really
cool place to chill in.

427
00:20:54,078 --> 00:20:55,478
Narrator: Halley
vi is without doubt

428
00:20:56,516 --> 00:20:58,125
the most complete
extreme environment

429
00:20:58,126 --> 00:20:59,388
accommodation ever built,

430
00:21:00,346 --> 00:21:01,869
but in the antarctic,

431
00:21:03,262 --> 00:21:04,740
mother nature
takes no prisoners.

432
00:21:04,741 --> 00:21:06,613
In 2016, a huge new
500-foot-deep crack

433
00:21:08,571 --> 00:21:12,618
appeared in the ice shelf.

434
00:21:12,619 --> 00:21:14,259
Just 18 miles from
halley and moving fast,

435
00:21:15,186 --> 00:21:17,580
it posed a grave risk to
the station and the team.

436
00:21:19,800 --> 00:21:23,542
Hugh: This crack was discovered
on the 31st of October 2016,

437
00:21:23,543 --> 00:21:27,459
so it's known as
the Halloween crack,

438
00:21:27,460 --> 00:21:29,288
and it was moving at some speed,

439
00:21:30,550 --> 00:21:32,552
and so they then
took the decision

440
00:21:34,293 --> 00:21:36,096
that because there was one
crack going in one direction

441
00:21:36,120 --> 00:21:38,079
and another at 90 degrees,

442
00:21:39,950 --> 00:21:41,516
that the new site for halley vi
had become far more dynamic

443
00:21:41,517 --> 00:21:43,911
than they had
originally envisaged

444
00:21:45,565 --> 00:21:47,525
and there was risk of
leaving people over a winter

445
00:21:48,176 --> 00:21:50,657
of not knowing how those
two cracks would interact.

446
00:21:53,268 --> 00:21:55,705
Narrator: They decided to act.

447
00:21:57,446 --> 00:21:59,526
It was time to test out
halley vi's built-in mobility

448
00:21:59,622 --> 00:22:01,668
and move the base to
safety and a new site inland.

449
00:22:07,978 --> 00:22:10,435
It was a timely reminder of how
brilliant engineering and design

450
00:22:10,459 --> 00:22:12,896
can make the
impossible possible.

451
00:22:13,984 --> 00:22:16,465
Hugh: You know, somebody living

452
00:22:17,771 --> 00:22:19,598
in an antarctic
research station,

453
00:22:19,599 --> 00:22:21,239
you know, their life
is at risk constantly

454
00:22:22,428 --> 00:22:25,908
because of the
extreme environment,

455
00:22:25,909 --> 00:22:27,693
so you need to think
of every single situation.

456
00:22:27,694 --> 00:22:29,814
You know, building a
research station in the antarctic

457
00:22:30,827 --> 00:22:32,785
is equivalent to building
a formula one racing car,

458
00:22:32,786 --> 00:22:34,851
and, you know, you just
can't leave anything to chance.

459
00:22:34,875 --> 00:22:36,964
You know, there are a
number of parameters

460
00:22:38,052 --> 00:22:39,488
that you have to design within,

461
00:22:41,316 --> 00:22:43,468
and you have to give each
of them a great deal of respect

462
00:22:43,492 --> 00:22:45,711
because failure to do
so will be catastrophic.

463
00:22:45,712 --> 00:22:47,888
♪

464
00:22:54,111 --> 00:22:56,897
♪

465
00:23:01,902 --> 00:23:05,992
Narrator: 5,900 miles
north of the antarctic circle,

466
00:23:05,993 --> 00:23:08,169
just off the coast of Morocco,
are the Canary Islands.

467
00:23:09,866 --> 00:23:13,391
With year-round
sunshine and warmth,

468
00:23:13,392 --> 00:23:15,002
buildings here have no need

469
00:23:16,656 --> 00:23:17,699
to protect their occupants
from harsh weather.

470
00:23:17,700 --> 00:23:21,964
Instead, they can be built

471
00:23:21,965 --> 00:23:23,749
purely to celebrate their
surroundings and purpose,

472
00:23:23,750 --> 00:23:26,100
which is exactly what
this incredible concert hall

473
00:23:27,275 --> 00:23:30,104
was built to do.

474
00:23:31,453 --> 00:23:32,733
Its 426-foot-long,
3,500-ton arch

475
00:23:34,108 --> 00:23:36,545
is engineered to hover
above the auditoria below.

476
00:23:38,417 --> 00:23:40,767
Ellie: It's an incredible
optical illusion.

477
00:23:42,595 --> 00:23:44,876
It looks like the wing is
floating completely unsupported.

478
00:23:45,032 --> 00:23:47,469
Corina kwami:
It's the improbable

479
00:23:48,383 --> 00:23:50,297
made to look impossible.

480
00:23:50,298 --> 00:23:51,907
Narrator: Inside
is a stunning space

481
00:23:51,908 --> 00:23:54,649
for over 2,000 music lovers,

482
00:23:54,650 --> 00:23:57,043
but it's outside where the
building hits the high notes.

483
00:23:57,044 --> 00:23:59,394
The incredible 190-foot-tall
arch is only possible

484
00:24:01,309 --> 00:24:03,703
thanks to a secret
skeleton of hard-core steel.

485
00:24:05,313 --> 00:24:07,576
The concrete cladding
that creates its skin

486
00:24:09,230 --> 00:24:11,070
was so pioneering, an
extraordinary new machine

487
00:24:11,406 --> 00:24:13,452
had to be
custom-built to make it.

488
00:24:14,322 --> 00:24:16,237
Curved walls glisten

489
00:24:17,760 --> 00:24:19,021
with over three million
tiny handmade tiles,

490
00:24:19,022 --> 00:24:20,862
and the giant wing
flexes in the powerful wind.

491
00:24:21,634 --> 00:24:25,767
Auditorio De tenerife

492
00:24:25,768 --> 00:24:27,029
is a stunning
engineering performance.

493
00:24:27,030 --> 00:24:29,250
So, how did they build it?

494
00:24:33,689 --> 00:24:35,517
In 1997, work began
on a new concert hall

495
00:24:37,214 --> 00:24:39,260
in Santa Cruz De tenerife
in the Canary Islands.

496
00:24:41,567 --> 00:24:44,004
Spanish modernist
architect Santiago calatrava,

497
00:24:45,701 --> 00:24:47,901
who'd recently finished the
awesome oculus transport hub

498
00:24:48,835 --> 00:24:53,012
in New York's trade centre,

499
00:24:53,013 --> 00:24:54,796
had designed a building that
could match any music venue

500
00:24:54,797 --> 00:24:56,797
in the world for visual
drama, both inside and out.

501
00:24:59,846 --> 00:25:03,936
His design of flowing forms

502
00:25:03,937 --> 00:25:05,459
performing impossible
engineering gymnastics,

503
00:25:05,460 --> 00:25:07,810
all clad in seamless concrete,

504
00:25:09,508 --> 00:25:11,355
would be one of the greatest
construction challenges

505
00:25:11,379 --> 00:25:14,121
of its time.

506
00:25:16,602 --> 00:25:19,691
The most difficult to build

507
00:25:19,692 --> 00:25:21,475
would be the three
curved components

508
00:25:21,476 --> 00:25:23,172
at the heart of the structure.

509
00:25:23,173 --> 00:25:26,088
Each would have a nickname.

510
00:25:26,089 --> 00:25:28,089
The nut would be the
147-foot-high central building

511
00:25:28,962 --> 00:25:33,226
to house the two
performance auditoriums.

512
00:25:33,227 --> 00:25:35,427
It would also provide a
single point of crucial support.

513
00:25:36,622 --> 00:25:39,102
The nut would be
flanked by the two sails.

514
00:25:40,756 --> 00:25:42,556
The curving slabs are
actually the outer walls

515
00:25:42,715 --> 00:25:44,630
of the main concert hall.

516
00:25:45,544 --> 00:25:47,328
On top is the wing.

517
00:25:49,243 --> 00:25:51,683
This massive structure, weighing
the same as ten 747 aircraft,

518
00:25:52,463 --> 00:25:55,118
would be made of a steel frame,

519
00:25:56,859 --> 00:25:58,730
clad in a thin layer of
ingeniously cast concrete.

520
00:25:58,731 --> 00:26:01,124
It would rest on that
small point of support

521
00:26:02,038 --> 00:26:04,127
provided by the nut.

522
00:26:05,651 --> 00:26:07,739
Debbie: To create
a structure like this,

523
00:26:07,740 --> 00:26:09,610
there is no
off-the-shelf solution.

524
00:26:09,611 --> 00:26:11,481
You have to create
something entirely from scratch.

525
00:26:11,482 --> 00:26:13,354
Narrator: The bespoke
building technique

526
00:26:14,877 --> 00:26:16,878
that was key to the
creation of the auditorio

527
00:26:16,879 --> 00:26:18,959
was the concrete formwork
that produced its cladding.

528
00:26:20,317 --> 00:26:22,717
Joshua: The simplest form would
be to take two wooden boards,

529
00:26:23,582 --> 00:26:27,062
support them in place,

530
00:26:27,063 --> 00:26:28,411
put reinforced concrete
in the gap in between,

531
00:26:28,412 --> 00:26:29,892
fill it all with
concrete, let it set,

532
00:26:31,372 --> 00:26:33,252
and take the boards
away, and you've got a wall.

533
00:26:33,592 --> 00:26:35,112
Narrator: Concrete
formwork can be used

534
00:26:35,811 --> 00:26:37,812
like blocks to build walls,

535
00:26:37,813 --> 00:26:40,206
one layer added
on top of another,

536
00:26:40,207 --> 00:26:42,287
as many times as the steel
reinforcing inside allows.

537
00:26:43,471 --> 00:26:45,951
Stacking layers like this is how
engineers virtually hand-built

538
00:26:47,823 --> 00:26:50,391
the huge concrete
walls of the sails,

539
00:26:51,479 --> 00:26:55,090
but the massive arcing wing

540
00:26:55,091 --> 00:26:56,918
would present a completely
different challenge

541
00:26:56,919 --> 00:26:58,573
and a solution that
was a world first.

542
00:27:00,880 --> 00:27:03,317
By 2001, the nut and sails
were structurally complete.

543
00:27:05,536 --> 00:27:07,974
It was time to
build the giant wing.

544
00:27:09,323 --> 00:27:11,412
Like the sails, the
surface of the wing

545
00:27:12,500 --> 00:27:15,284
would be concrete formwork,

546
00:27:15,285 --> 00:27:17,133
but hidden inside would be
the heavy-duty engineering

547
00:27:17,157 --> 00:27:19,420
that made this
outrageous shape possible.

548
00:27:21,117 --> 00:27:23,037
A huge steel framework
was prefabricated in Spain

549
00:27:24,512 --> 00:27:26,993
and shipped in 17 pieces,

550
00:27:28,777 --> 00:27:30,494
before being assembled
into larger sections on site.

551
00:27:30,518 --> 00:27:32,781
Juan Carlos was
the site engineer.

552
00:27:34,653 --> 00:27:36,674
Juan Carlos ramflo ramos,
translated: Each piece weighed

553
00:27:36,698 --> 00:27:39,222
around 200 to 250 tons.

554
00:27:41,007 --> 00:27:43,087
They were lifted with a
crane, and once they were up,

555
00:27:44,488 --> 00:27:46,528
a system put together the
mobile and the fixed part,

556
00:27:47,622 --> 00:27:50,146
welded it, and then let it go.

557
00:27:50,886 --> 00:27:53,801
It's unique.

558
00:27:53,802 --> 00:27:57,022
Corina: You have
a steel skeleton

559
00:27:57,023 --> 00:27:58,937
that was constructed
to give the whole thing

560
00:27:58,938 --> 00:28:00,578
a rigidity and strength,
24 rows of beams.

561
00:28:02,245 --> 00:28:06,118
Narrator: Once the steel frame
of the wing was assembled,

562
00:28:06,119 --> 00:28:09,121
scaffolding was built
under the inner areas

563
00:28:09,122 --> 00:28:10,882
to support traditional
wooden formwork molds.

564
00:28:12,386 --> 00:28:14,823
But using formwork to
make the concrete outer shell

565
00:28:16,520 --> 00:28:18,400
on the huge areas of the
wing was not an option.

566
00:28:19,828 --> 00:28:22,148
The scaffolding required to
work at such heights and angles

567
00:28:23,876 --> 00:28:26,400
would have made the
build impossibly slow,

568
00:28:27,314 --> 00:28:28,881
complex, and expensive.

569
00:28:30,360 --> 00:28:32,120
These problems meant
the construction company

570
00:28:33,494 --> 00:28:35,451
had to come up with
something special.

571
00:28:35,452 --> 00:28:37,280
[Speaking Spanish]

572
00:28:38,847 --> 00:28:41,153
Juan Carlos: With
the wing, the big curve,

573
00:28:41,154 --> 00:28:42,954
this was such a complex
process of engineering

574
00:28:43,547 --> 00:28:46,941
that they had to design
a special machine

575
00:28:46,942 --> 00:28:48,422
to put the iron
and the concrete in,

576
00:28:50,032 --> 00:28:53,295
and this was supported
by the same steel wing.

577
00:28:53,296 --> 00:28:55,255
It's unique and was
built especially to do that.

578
00:28:59,346 --> 00:29:02,957
Narrator: This machine
is called a carriage crane.

579
00:29:02,958 --> 00:29:05,352
It was assembled on
the back of the wing,

580
00:29:06,919 --> 00:29:08,528
and its huge arms wrapped
around and underneath

581
00:29:08,529 --> 00:29:10,966
to support the formwork.

582
00:29:12,838 --> 00:29:14,998
Adjustable in every direction
and guided on huge rails,

583
00:29:16,189 --> 00:29:18,582
it enabled concrete to
be attached along the wing

584
00:29:19,975 --> 00:29:21,890
in previously
unreachable places.

585
00:29:24,284 --> 00:29:26,634
Hayley: This was a very slow
process to create the wing.

586
00:29:27,722 --> 00:29:30,507
@they had to align the formwork,

587
00:29:32,031 --> 00:29:34,162
pour the concrete,
let the concrete set,

588
00:29:34,163 --> 00:29:37,513
then move the machine
up and realign the formwork

589
00:29:37,514 --> 00:29:39,594
in a different, narrower
shape and a different angle,

590
00:29:40,474 --> 00:29:43,781
and then re-pour the
concrete and let it set

591
00:29:43,782 --> 00:29:45,914
and repeat that 32 times.

592
00:29:47,960 --> 00:29:50,397
Narrator: The final result is
an extraordinary fluid shape

593
00:29:52,138 --> 00:29:54,298
that, despite weighing 3,500
tons, appears to levitate.

594
00:29:57,621 --> 00:30:00,146
Debbie: This is an
amazing optical illusion

595
00:30:02,017 --> 00:30:04,192
because when you look at
it, it just looks like this wing

596
00:30:04,193 --> 00:30:05,633
is just completely
floating in space,

597
00:30:06,326 --> 00:30:09,197
but from certain angles,

598
00:30:09,198 --> 00:30:11,112
you can see behind
the smoke and mirrors.

599
00:30:11,113 --> 00:30:13,153
Narrator: The wing is
supported at just five points,

600
00:30:13,202 --> 00:30:15,002
an amazing feat considering
the powerful winds

601
00:30:16,379 --> 00:30:18,539
that almost constantly sweep
across the Canary Islands.

602
00:30:18,817 --> 00:30:21,602
But one of these supports

603
00:30:23,169 --> 00:30:24,212
is a special, steel,
shock-absorbing tube

604
00:30:24,213 --> 00:30:27,476
that moves up and
down with the wing

605
00:30:27,477 --> 00:30:28,869
to stop it from tearing
itself off the building.

606
00:30:28,870 --> 00:30:31,177
Ellie: In really high winds,

607
00:30:32,656 --> 00:30:34,222
you can hear it just
bouncing up and down,

608
00:30:34,223 --> 00:30:35,783
which I'm sure
sounds pretty terrifying,

609
00:30:37,313 --> 00:30:39,033
but I'm sure they knew
what they were doing.

610
00:30:40,142 --> 00:30:41,982
Narrator: The auditorio's
architect, calatrava,

611
00:30:43,537 --> 00:30:45,843
wasn't satisfied with
just making the concrete

612
00:30:45,844 --> 00:30:49,629
achieve impossible shapes.

613
00:30:49,630 --> 00:30:52,070
He wanted his building to have
an outstanding surface as well.

614
00:30:52,676 --> 00:30:55,027
The concrete was mixed
with a high proportion

615
00:30:56,898 --> 00:30:59,258
of sand and titanium dioxide
to brighten it almost to white,

616
00:31:00,597 --> 00:31:03,035
but calatrava wanted more.

617
00:31:04,732 --> 00:31:06,646
To make the building
gleam, he wanted it covered

618
00:31:06,647 --> 00:31:09,041
in 3 1/2 million tiles,

619
00:31:10,520 --> 00:31:13,131
all hand-laid in a
style called trencadís.

620
00:31:13,132 --> 00:31:15,743
But surely, even
on this project,

621
00:31:16,831 --> 00:31:18,485
that was too going too far.

622
00:31:20,313 --> 00:31:22,183
@miriam Gil: Basically trencadis
means broken ceramic tiles

623
00:31:22,184 --> 00:31:26,274
all together on the
same work, right?

624
00:31:26,275 --> 00:31:28,035
Anyway, mosaics is
good, and I will show you,

625
00:31:28,060 --> 00:31:30,758
@they're one-square-meter panels

626
00:31:32,455 --> 00:31:34,455
that came pre-madeúon a
flexible net from valencia,

627
00:31:34,762 --> 00:31:37,634
with different numbers.

628
00:31:39,201 --> 00:31:41,041
You can see like a wave,
a zigzag curve, right?

629
00:31:41,812 --> 00:31:44,511
Can't you?

630
00:31:46,208 --> 00:31:48,128
And just one meter up,
there is another one here.

631
00:31:50,038 --> 00:31:52,519
Right? And there is
another one over there.

632
00:31:54,869 --> 00:31:57,524
Once you have this information,

633
00:31:59,047 --> 00:32:00,927
you can see the different
levels of the surface.

634
00:32:01,049 --> 00:32:03,530
We have made a
Jigsaw puzzle here.

635
00:32:07,490 --> 00:32:09,251
Juan Carlos: Truly, the
only word that comes to mind

636
00:32:09,275 --> 00:32:13,321
is spectacular.

637
00:32:13,322 --> 00:32:15,106
The effect you get
when the music plays,

638
00:32:15,107 --> 00:32:16,507
something that
truly transports you.

639
00:32:21,809 --> 00:32:23,810
Narrator: Close inspection
may reveal a small cheat,

640
00:32:23,811 --> 00:32:25,851
but stand back, and its
full effect is plain to see.

641
00:32:28,250 --> 00:32:30,687
It all adds to create a
glistening introduction

642
00:32:31,775 --> 00:32:34,342
to a music lover's evening.

643
00:32:34,343 --> 00:32:36,693
♪

644
00:32:45,876 --> 00:32:48,236
In Scotland, in the mid-1990s,
an audacious plan was hatched

645
00:32:50,707 --> 00:32:53,101
to reconnect two of
britain's most historic canals.

646
00:32:54,973 --> 00:32:57,584
They were only 980 feet apart,

647
00:32:59,281 --> 00:33:01,201
but one was almost 80
feet higher than the other.

648
00:33:01,936 --> 00:33:04,591
For waterways that were once

649
00:33:06,288 --> 00:33:06,810
the superhighways of
the industrial revolution,

650
00:33:06,811 --> 00:33:09,422
that is worlds apart.

651
00:33:10,901 --> 00:33:12,581
But an effort to
reconnect these two canals

652
00:33:14,253 --> 00:33:16,254
overcame the huge problem,
with an engineering solution

653
00:33:16,255 --> 00:33:18,997
of stunning simplicity
and efficiency.

654
00:33:21,173 --> 00:33:23,610
Hayley: This is the
only Ferris wheel boat lift

655
00:33:24,393 --> 00:33:26,439
in the world.

656
00:33:27,918 --> 00:33:30,268
Narrator: This is
the falkirk wheel...

657
00:33:30,269 --> 00:33:32,400
A fusion of sculpture
and engineering,

658
00:33:32,401 --> 00:33:34,621
breathing new life
into a historic canal,

659
00:33:36,318 --> 00:33:39,581
and now a tourist
destination in its own right.

660
00:33:39,582 --> 00:33:41,782
The wheel can effortlessly
lift nearly 500 tons of water

661
00:33:43,456 --> 00:33:47,633
and two boats 78 feet,

662
00:33:47,634 --> 00:33:49,434
while not spilling a
drop or breaking a sweat.

663
00:33:50,550 --> 00:33:53,031
So, how did they build it?

664
00:33:55,207 --> 00:33:57,644
250 years ago,
these narrow channels

665
00:33:59,211 --> 00:34:01,474
helped transport goods
around the country,

666
00:34:02,779 --> 00:34:04,564
fuelling britain's
booming economy.

667
00:34:05,652 --> 00:34:08,176
Here, the beautiful union canal

668
00:34:09,482 --> 00:34:12,136
runs to Glasgow
in one direction,

669
00:34:12,137 --> 00:34:14,457
and the forth and Clyde canal
runs to Edinburgh in the other.

670
00:34:15,488 --> 00:34:19,317
Corina: These canals
were the lifeblood

671
00:34:19,318 --> 00:34:21,014
@connecting
Edinburgh and Glasgow

672
00:34:21,015 --> 00:34:23,190
during the
industrial revolution,

673
00:34:23,191 --> 00:34:24,951
and it also provided a
luxury high-speed service,

674
00:34:24,975 --> 00:34:28,543
the bullet train of its day.

675
00:34:28,544 --> 00:34:30,384
Narrator: The waterways
were completely reliant

676
00:34:31,634 --> 00:34:33,287
on a system of locks, which
allowed these two canals

677
00:34:33,288 --> 00:34:35,508
at different heights
to be connected.

678
00:34:37,205 --> 00:34:39,085
But by the late 1800s,
trains were all the rage,

679
00:34:40,165 --> 00:34:42,515
and the canals and crucial
lock system between them

680
00:34:43,385 --> 00:34:45,605
were barely used.

681
00:34:46,954 --> 00:34:48,354
Corina: Due to the
height difference

682
00:34:49,609 --> 00:34:51,349
between the forth and
Clyde and the union canals,

683
00:34:51,350 --> 00:34:53,568
11 locks were needed to get
the boats from one to the other,

684
00:34:53,569 --> 00:34:57,442
but these fell into
disrepair in the 1930s.

685
00:34:57,443 --> 00:34:59,271
Narrator: Not surprising
when you consider

686
00:35:00,794 --> 00:35:02,011
that taking a boat
through these 11 locks

687
00:35:02,012 --> 00:35:05,363
took almost an entire day.

688
00:35:05,364 --> 00:35:07,627
Eventually, they
were demolished,

689
00:35:09,368 --> 00:35:10,455
and the stretch of locks and
the waterway between them

690
00:35:10,456 --> 00:35:12,893
lay unused.

691
00:35:14,764 --> 00:35:16,655
Glasgow and Edinburgh were
no longer connected by canal.

692
00:35:16,679 --> 00:35:20,813
Tony kettle: It was broken,
fractured you might say,

693
00:35:20,814 --> 00:35:23,053
during the 1960s and '70s,
úwith roads and other obstacles.

694
00:35:23,077 --> 00:35:26,601
Narrator: By the mid-1990s,
canals were back in fashion,

695
00:35:26,602 --> 00:35:30,692
now used for pleasure
rather than industry.

696
00:35:30,693 --> 00:35:32,739
British waterways wanted
the old route restored.

697
00:35:33,914 --> 00:35:36,308
To join the canals,

698
00:35:37,265 --> 00:35:39,005
they would have to dig

699
00:35:39,006 --> 00:35:40,963
a new canal,

700
00:35:40,964 --> 00:35:42,574
but overcoming a massive
height difference was tricky.

701
00:35:42,575 --> 00:35:45,881
Rebuilding the hopelessly
slow staircase of locks

702
00:35:45,882 --> 00:35:48,042
that once connected the
two canals at different heights

703
00:35:48,189 --> 00:35:50,757
was not an option,

704
00:35:52,628 --> 00:35:54,988
so in the mid-1990s, the search
for a modern solution began.

705
00:35:55,240 --> 00:35:57,590
The design that was
given the go-ahead

706
00:35:58,895 --> 00:36:00,215
was a completely
original concept.

707
00:36:01,550 --> 00:36:03,510
Tony: This is the world's
first rotating boat lift

708
00:36:04,205 --> 00:36:05,885
that can take boats
in a circular direction

709
00:36:06,033 --> 00:36:07,339
from one canal to the other.

710
00:36:08,862 --> 00:36:10,702
What we've created
here is a piece of sculpture

711
00:36:11,473 --> 00:36:13,633
that becomes a landmark
and a destination for Scotland.

712
00:36:14,128 --> 00:36:16,609
Narrator: The falkirk wheel is
a 200-ton steel Ferris wheel,

713
00:36:18,872 --> 00:36:21,353
with two gondolas, or caissons,

714
00:36:22,745 --> 00:36:24,185
pivoting around a
giant central axle.

715
00:36:25,966 --> 00:36:28,446
The caissons act as huge buckets
that hold water and the boats.

716
00:36:29,970 --> 00:36:32,538
The wheel turns, moving the
boats and 500 tons of water,

717
00:36:34,453 --> 00:36:36,803
to connect them 78 feet above
or below to the other canal.

718
00:36:40,110 --> 00:36:42,548
At the top, it's all
connected by an aqueduct

719
00:36:44,027 --> 00:36:45,812
that would have done
the romans proud.

720
00:36:50,425 --> 00:36:53,601
The romans would prove to
be this project's first obstacle.

721
00:36:53,602 --> 00:36:57,605
A Roman earth
fortification once stood here.

722
00:36:57,606 --> 00:36:59,782
Today, all that's
left is a grassy hill.

723
00:37:00,696 --> 00:37:04,917
But 2,000 years ago,

724
00:37:04,918 --> 00:37:06,417
it was the northernmost
border of the Roman empire.

725
00:37:06,441 --> 00:37:10,227
Jim Steele: Where we stand is

726
00:37:10,228 --> 00:37:11,141
a unesco world heritage site,

727
00:37:11,142 --> 00:37:12,882
which is the antonine wall

728
00:37:13,970 --> 00:37:15,623
and that was built in a.D. 142,

729
00:37:15,624 --> 00:37:18,844
so we had to
actually get the canal

730
00:37:18,845 --> 00:37:21,063
underneath the antonine
wall, through a tunnel...

731
00:37:21,064 --> 00:37:23,464
@the tunnel was about 200
meters long, 8 meter in diameter...

732
00:37:24,024 --> 00:37:25,765
On to the north side
of the antonine wall,

733
00:37:26,853 --> 00:37:28,855
extend it on to an aqueduct

734
00:37:30,030 --> 00:37:31,310
and then on to
the falkirk wheel.

735
00:37:33,163 --> 00:37:35,185
Narrator: Digging a 650-foot
tunnel under the antonine wall

736
00:37:35,209 --> 00:37:37,907
was achieved without drama.

737
00:37:39,605 --> 00:37:41,485
Building an aqueduct
80 feet high over the basin

738
00:37:41,694 --> 00:37:45,653
was a more serious challenge.

739
00:37:45,654 --> 00:37:47,174
Jim: If you had been
here 20 years ago,

740
00:37:48,570 --> 00:37:50,679
what you would have seen is
a whole forest of scaffolding.

741
00:37:50,703 --> 00:37:53,705
So, everything was
supported by scaffolding,

742
00:37:53,706 --> 00:37:55,402
so it basically takes a
small part of the load

743
00:37:55,403 --> 00:37:58,536
of the wet concrete
as you're pouring it

744
00:37:58,537 --> 00:38:00,233
and as the four
piers are poured,

745
00:38:00,234 --> 00:38:02,149
the gap to the deck itself,

746
00:38:04,064 --> 00:38:05,586
that's all supported and all
constructed in four sections.

747
00:38:05,587 --> 00:38:07,894
Narrator: No one had
built a canal in Scotland

748
00:38:08,677 --> 00:38:12,027
for 200 years.

749
00:38:12,028 --> 00:38:14,348
That lack of practice initially
caused a few more problems.

750
00:38:15,031 --> 00:38:17,391
Jim: Inevitably there were
some leaks, not in the structure,

751
00:38:19,035 --> 00:38:21,254
I would have to say, but
in actually the earthworks

752
00:38:21,255 --> 00:38:23,865
approaching to the viaduct.

753
00:38:23,866 --> 00:38:25,946
But over a series of a few
weeks or months, you know,

754
00:38:26,042 --> 00:38:28,523
we actually plugged all the gaps

755
00:38:29,916 --> 00:38:32,700
in the waterproofing
of the canal.

756
00:38:32,701 --> 00:38:34,221
And then on we go,
and to my knowledge,

757
00:38:36,096 --> 00:38:38,536
it's never had a problem in the
20 years since it's been open.

758
00:38:41,057 --> 00:38:43,494
Narrator: With the
forth and Clyde canal

759
00:38:43,495 --> 00:38:44,886
connected through
to the aqueduct,

760
00:38:44,887 --> 00:38:46,287
the wheel itself
could be installed.

761
00:38:49,631 --> 00:38:51,154
This system required trapping

762
00:38:52,460 --> 00:38:54,287
250 tons of water
in each caisson

763
00:38:54,288 --> 00:38:56,725
and moving one up
and the other down

764
00:38:57,813 --> 00:38:59,119
78 feet to the basin below.

765
00:39:01,034 --> 00:39:03,515
To engineer a structure
able to carry 500 tons of water

766
00:39:05,299 --> 00:39:07,867
on the end of two steel arms

767
00:39:09,390 --> 00:39:11,304
while keeping everything
steady and under control

768
00:39:11,305 --> 00:39:13,307
meant relying on some
key laws of physics.

769
00:39:14,613 --> 00:39:19,051
Tony: It's like a balanced beam,

770
00:39:19,052 --> 00:39:20,400
and that weight really
means it's very, very efficient,

771
00:39:20,401 --> 00:39:22,837
and the water and
the boat balances out,

772
00:39:22,838 --> 00:39:25,840
so we had this unique
balanced beam idea,

773
00:39:25,841 --> 00:39:28,191
that I don't think
there's another boat lift

774
00:39:29,236 --> 00:39:30,671
that uses that principle.

775
00:39:30,672 --> 00:39:32,194
It uses other
elevator-type principles

776
00:39:32,195 --> 00:39:34,588
with weights and things,
but not a balanced beam,

777
00:39:34,589 --> 00:39:37,069
which is the
fundamental system here.

778
00:39:37,070 --> 00:39:40,638
Narrator: The natural balance
of having equal amounts

779
00:39:40,639 --> 00:39:41,919
of water at each
end makes sense,

780
00:39:42,815 --> 00:39:44,207
if both caissons
are holding boats.

781
00:39:45,818 --> 00:39:47,538
But how does the falkirk
wheel stay balanced

782
00:39:48,298 --> 00:39:49,618
if it's only
transporting one boat

783
00:39:50,475 --> 00:39:53,172
and the other caisson is empty?

784
00:39:53,173 --> 00:39:56,002
To answer the question,

785
00:39:57,830 --> 00:39:59,950
engineers made clever use
of the Archimedes principle.

786
00:40:02,617 --> 00:40:04,532
Tony: Archimedes
had a Eureka moment

787
00:40:06,273 --> 00:40:08,294
when he realized that if
he put an object in his bath,

788
00:40:08,318 --> 00:40:11,060
the weight of the object

789
00:40:12,453 --> 00:40:13,888
was displaced
exactly with the water,

790
00:40:13,889 --> 00:40:15,169
and it's the same
principle here.

791
00:40:16,936 --> 00:40:19,981
Nehemiah: So, in this case, as
a boat floats into the chamber,

792
00:40:19,982 --> 00:40:21,782
it's going to remove the
exact amount of water

793
00:40:23,116 --> 00:40:24,636
that's equal to the
weight of the boat,

794
00:40:25,945 --> 00:40:27,598
so that means that
as long as you keep

795
00:40:27,599 --> 00:40:28,817
the water levels the same,

796
00:40:30,340 --> 00:40:31,900
it's going to continue
to weigh the same

797
00:40:32,342 --> 00:40:35,083
with or without the boat.

798
00:40:35,084 --> 00:40:36,998
Narrator: Now, the massive
payload needs to be rotated.

799
00:40:36,999 --> 00:40:39,439
@hayley: Normally moving 500
tons of water 24 meters in the air

800
00:40:42,396 --> 00:40:45,094
@takes the same amount of energy

801
00:40:46,618 --> 00:40:48,378
as a typical Scottish
household over three days,

802
00:40:48,402 --> 00:40:51,231
but all the falkirk wheel needs

803
00:40:52,885 --> 00:40:54,805
is the equivalent power
of eight boiling kettles.

804
00:40:55,191 --> 00:40:57,551
Narrator: The balancing act
means the wheel is easy to turn.

805
00:40:59,021 --> 00:41:01,459
As the wheel lifts one tank,

806
00:41:03,156 --> 00:41:04,373
the downward force of
the tank on the other side

807
00:41:04,374 --> 00:41:07,899
does most of the work.

808
00:41:07,900 --> 00:41:09,509
Like a seesaw, water
keeps the wheel balanced,

809
00:41:09,510 --> 00:41:12,078
but it creates another problem.

810
00:41:13,558 --> 00:41:15,198
Each massive tank
contains 66,000 gallons,

811
00:41:16,256 --> 00:41:18,693
and if this water starts
sloshing from side to side,

812
00:41:19,607 --> 00:41:23,915
there could be trouble.

813
00:41:23,916 --> 00:41:25,873
Corina: The biggest
problem is the water.

814
00:41:25,874 --> 00:41:27,874
You have to keep the
gondolas, or the tanks, level.

815
00:41:28,007 --> 00:41:30,009
Plus, when you
start to move water,

816
00:41:31,837 --> 00:41:33,728
it creates a critical mass
that's really hard to stop.

817
00:41:33,752 --> 00:41:36,276
The entire structure
could tip over

818
00:41:37,669 --> 00:41:39,844
if it's not carefully
controlled.

819
00:41:39,845 --> 00:41:41,759
Tony: We had to solve the
problem of how to stop the water

820
00:41:41,760 --> 00:41:43,109
from making the
caissons turn over

821
00:41:44,980 --> 00:41:46,981
because as you move them
round, they're inherently unstable.

822
00:41:46,982 --> 00:41:50,071
You know, if you
take a ferry full of water

823
00:41:50,072 --> 00:41:51,986
and the water flows
from one side to the other,

824
00:41:51,987 --> 00:41:53,667
you know, it's very
difficult to control it

825
00:41:54,207 --> 00:41:56,948
once it starts to move.

826
00:41:56,949 --> 00:41:59,069
Narrator: The best solution
proved to be the simplest.

827
00:41:59,604 --> 00:42:02,041
Tony: It's connected by a
simple system of cogs and wheels,

828
00:42:03,782 --> 00:42:05,942
and we have five cogs, of
which the central one's fixed

829
00:42:06,828 --> 00:42:09,178
and the outer two are
fixed to the caissons,

830
00:42:10,484 --> 00:42:12,051
and then the two
wheels in between

831
00:42:13,443 --> 00:42:14,763
are allowed to
freely move around,

832
00:42:15,794 --> 00:42:17,577
and what they do is
they allow caissons

833
00:42:17,578 --> 00:42:19,406
to always remain horizontal,

834
00:42:20,799 --> 00:42:22,539
no matter what
forces are applied

835
00:42:22,540 --> 00:42:24,193
to the two beams going around.

836
00:42:28,458 --> 00:42:30,219
Narrator: As the wheel turns,
the central axle drives cogs

837
00:42:30,243 --> 00:42:32,332
that run up the
arms of the wheel.

838
00:42:34,160 --> 00:42:36,161
These are geared to create
an always-correct connection

839
00:42:36,162 --> 00:42:40,382
to the caissons,

840
00:42:40,383 --> 00:42:42,036
which stops any internal
force affecting their position,

841
00:42:42,037 --> 00:42:44,431
prevents the caissons
from swinging out of control,

842
00:42:45,998 --> 00:42:47,638
and keeps them
permanently level and safe.

843
00:42:49,915 --> 00:42:52,352
The falkirk wheel is
the perfect marriage

844
00:42:53,875 --> 00:42:55,555
of beautiful design
and clever engineering,

845
00:42:56,574 --> 00:42:58,706
reconnecting a
historic canal route

846
00:42:59,794 --> 00:43:01,796
with a uniquely modern solution.

847
00:43:03,668 --> 00:43:05,908
Hayley: The finished wheel
is a piece of pure engineering

848
00:43:06,366 --> 00:43:08,716
meets Celtic sculpture,

849
00:43:10,065 --> 00:43:12,414
providing a breathtaking example

850
00:43:12,415 --> 00:43:14,655
of how human problem-solving
can achieve the spectacular.

851
00:43:16,768 --> 00:43:19,205
Jim: It's still very
well-attended,

852
00:43:20,902 --> 00:43:22,982
it's one of the main tourist
attractions in Scotland,

853
00:43:23,296 --> 00:43:24,976
and it actually sits
as an iconic structure

854
00:43:25,907 --> 00:43:27,387
within all the other
iconic structures

855
00:43:28,301 --> 00:43:30,258
that have been built in
the UK and in Scotland.

856
00:43:30,259 --> 00:43:32,259
And again, very proud to
have been part of the team

857
00:43:32,610 --> 00:43:34,612
that actually delivered this.

858
00:43:37,789 --> 00:43:39,462
Tony: It's in the British
passport, you know,

859
00:43:39,486 --> 00:43:41,835
it's on the Scottish pound note,

860
00:43:41,836 --> 00:43:43,663
and it's really great
that something of today

861
00:43:43,664 --> 00:43:45,945
that takes old technology
and reuses it in a different way

862
00:43:46,145 --> 00:43:48,065
and is innovative in the
way it approaches things

863
00:43:48,495 --> 00:43:49,801
and is actually celebrated,

864
00:43:51,498 --> 00:43:53,238
and I think that's the
best thing of all, you know.

865
00:43:53,239 --> 00:43:55,109
If people can enjoy and
know that there's a future

866
00:43:55,110 --> 00:43:56,790
and there are more
things to be discovered,

867
00:43:57,591 --> 00:43:59,158
@that's the most exciting thing.

868
00:43:59,680 --> 00:44:01,290
♪