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--captions by vitac--
Www.Vitac.Com
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00:00:04,793 --> 00:00:07,793
Captions paid for by
Discovery communications
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Narrator: traffic-signal poles
Must be strong enough
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00:00:56,137 --> 00:00:59,068
To bear the weight
Of road signs, street lights,
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00:00:59,068 --> 00:01:01,620
And, of course, traffic signals.
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00:01:01,620 --> 00:01:04,206
The poles are also built
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00:01:04,206 --> 00:01:06,724
To withstand
Extreme weather conditions,
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00:01:06,724 --> 00:01:11,000
Such as high winds
And heavy snow accumulation.
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00:01:12,586 --> 00:01:16,310
Traffic signal poles
Are made of high-strength steel.
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00:01:16,310 --> 00:01:19,620
Years of weather exposure
Can cause corrosion,
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00:01:19,620 --> 00:01:23,551
So the poles are galvanized
On both sides for protection.
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00:01:23,551 --> 00:01:25,793
Each pole
Has a welded plate
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00:01:25,793 --> 00:01:28,931
To connect it
To a perpendicular pole.
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00:01:28,931 --> 00:01:32,551
The poles are made out
Of these steel sheets.
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00:01:32,551 --> 00:01:35,620
The steel arrives at the factory
In one large roll.
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00:01:35,620 --> 00:01:40,000
They use a decoiler to unwind
The sheet and flatten it out.
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Then a shear cuts it
To the correct length.
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00:01:46,310 --> 00:01:48,551
A computer-guided plasma cutter
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00:01:48,551 --> 00:01:51,862
Marks short lines
On both ends of the sheet.
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These lines indicate
Where to bend the flat sheet
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To form a round pole.
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00:01:59,482 --> 00:02:03,034
The machine cuts the sheet
Into a rectangular shape,
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00:02:03,034 --> 00:02:06,655
Or a trapezoid shape if the pole
Will taper at the top.
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00:02:09,310 --> 00:02:12,344
Workers number the machine lines
With chalk,
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00:02:12,344 --> 00:02:16,275
Giving lines directly opposite
Of each other the same number.
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00:02:16,275 --> 00:02:18,137
Then they transfer the sheet
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00:02:18,137 --> 00:02:21,448
To a bending machine
Called a press brake.
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00:02:27,517 --> 00:02:30,310
The press brake bends the sheet
Along the marked line
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00:02:30,310 --> 00:02:33,068
To a preprogrammed angle.
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00:02:37,655 --> 00:02:40,103
Workers use
A digital measuring device
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To make sure the first bend
Is accurate.
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If it is, they continue bending
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00:02:45,034 --> 00:02:47,896
Along the remainder
Of the lines,
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00:02:47,896 --> 00:02:52,310
Transforming the flat sheet
Into a multisided round pole.
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00:02:55,310 --> 00:02:57,965
Now the pole moves
To a welding station,
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00:02:57,965 --> 00:03:01,448
Where hydraulic rollers
Apply pressure from both sides.
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00:03:01,448 --> 00:03:04,689
This forces
The edges of the sheet together
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00:03:04,689 --> 00:03:08,896
So that a welding head can fuse
The seam with molten steel.
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00:03:08,896 --> 00:03:10,275
At the same time,
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00:03:10,275 --> 00:03:12,896
The head deposits
A granular powder called flux,
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00:03:12,896 --> 00:03:15,310
Which prevents air
From penetrating the weld
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00:03:15,310 --> 00:03:17,620
And weakening it.
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00:03:18,827 --> 00:03:21,793
Workers place the pole
In a hydraulic press
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So it doesn't warp as
The seam weld cools and shrinks.
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00:03:29,137 --> 00:03:32,103
Next,
A computer-guided plasma machine
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00:03:32,103 --> 00:03:35,379
Cuts a connection plate
Out of thick steel.
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00:03:35,379 --> 00:03:39,482
The machine also drills holes
For the high-strength bolts
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00:03:39,482 --> 00:03:42,827
Needed to attach the plate
To the traffic-signal pole.
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00:03:46,310 --> 00:03:48,103
Workers
Center the connection plate
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00:03:48,103 --> 00:03:52,655
On support plates they've
Already welded to the pole.
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00:03:54,034 --> 00:03:56,965
Then they weld
Everything in place.
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00:04:02,965 --> 00:04:06,000
Next, workers weld a baseplate
To the bottom of the pole.
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00:04:06,000 --> 00:04:08,000
It has holes
For the anchor bolts,
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Which are used for securing the
Traffic signal to the street.
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00:04:14,827 --> 00:04:17,965
Workers inspect the welds
With a testing device.
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00:04:17,965 --> 00:04:20,655
It uses an electric current
To magnetically draw
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00:04:20,655 --> 00:04:24,034
Colored powder
Into any defective area.
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00:04:24,034 --> 00:04:28,827
The factory ships the finished
Poles to a galvanizing plant,
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00:04:28,827 --> 00:04:32,931
Where they're dipped
In a series of wash tanks.
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00:04:32,931 --> 00:04:36,000
The plant's tanks
Are deep enough
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00:04:36,000 --> 00:04:39,655
To fully submerge the poles
So they can treat both the inner
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00:04:39,655 --> 00:04:42,793
And outer surface
At the same time.
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Now the poles go into a vat
Of sulfuric acid.
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00:04:46,620 --> 00:04:50,793
This bath dissolves
The more stubborn contaminants
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That washing can't remove.
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The next tank
Contains a chemical
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That weakens
The surface of the poles.
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00:04:58,034 --> 00:05:01,413
This allows the galvanizing
Metal to penetrate the steel,
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00:05:01,413 --> 00:05:03,241
Rather than sit on the surface.
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00:05:03,241 --> 00:05:08,000
The final tank
Contains molten zinc.
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00:05:13,517 --> 00:05:16,448
As the poles bathe
In the 842-degree zinc,
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Workers in fire-protection suits
Skim the surface
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To remove iron oxide
And ash that floats to the top.
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00:05:25,551 --> 00:05:28,724
This keeps the freshly
Galvanized surface clean
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As the poles are hoisted out of
The tank and set aside to cool.
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Because they're galvanized
Rather than painted,
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These poles are able to support
Traffic lights, signs,
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And street lamps
For 40 years or more.
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Narrator:
In 1908, a german housewife
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Came up with a solution to get
Rid of bitter-tasting sediment
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In her coffee.
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She punched nail holes in a pot
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00:06:05,724 --> 00:06:08,034
And covered them
With blotting paper.
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Then she placed ground coffee
On the paper
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And filled the pot
With hot water.
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It worked so well
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That she started selling
Her coffee filters worldwide.
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These coffee filters
Are made of 100% cellulose fiber
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00:06:22,103 --> 00:06:26,275
Harvested from slow-growing pine
And spruce trees
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00:06:26,275 --> 00:06:29,758
In the forests
Of southern scandinavia.
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The raw material produces paper
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That lets about 3 ounces
Of water pass through it
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In approximately 40 seconds.
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That's the optimal saturation
Rate for producing good coffee.
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30%
Of the paper's cellulose content
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Is left over
From earlier production.
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The other 70%
Is raw cellulose fiber.
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The materials go into a machine
Called a pulper,
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Which works
Like a giant food processor.
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00:06:57,379 --> 00:07:00,172
It blends the raw materials
With hot water,
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Making a fiber soup called pulp.
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00:07:07,827 --> 00:07:13,000
A paper-making machine
Spreads a one-inch layer of pulp
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00:07:13,000 --> 00:07:16,413
Across a wire-mesh belt.
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00:07:16,413 --> 00:07:19,655
Water jets cut a straight edge
On both sides.
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00:07:19,655 --> 00:07:22,931
As moisture drains down
Through the belt,
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00:07:22,931 --> 00:07:25,586
The pulp forms
A soggy sheet of paper.
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It has a water content of 80%.
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All this happens
At an astounding pace.
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The machine lays down
1,300 feet of pulp a minute.
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At the next station,
Heavy compression rollers
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Squeeze almost half the water
Out of the paper.
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A tool applies a crepe texture.
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This increases
The surface area of the paper
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00:07:52,724 --> 00:07:54,344
And improves filtration speed.
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Next,
They use 38 steam-heated rollers
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To dry the paper completely.
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The rollers'
Surface temperatures
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Are around 250 degrees.
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00:08:08,103 --> 00:08:11,482
As the finished paper
Exits the machine,
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00:08:11,482 --> 00:08:14,793
A camera
Registers the location of holes,
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00:08:14,793 --> 00:08:18,241
Dirt, or other defects
That have to be cut out.
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00:08:18,241 --> 00:08:21,758
It takes the machine 45 minutes
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00:08:21,758 --> 00:08:25,482
To produce an 11-mile-long sheet
Of coffee-filter paper.
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00:08:25,482 --> 00:08:29,034
The roll is transferred
To a cutting machine.
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The paper is sliced
Into two-foot rolls
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00:08:32,172 --> 00:08:35,241
So it can fit
In the filter-making machine.
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00:08:39,413 --> 00:08:41,413
Sensors
In the filter-making machine
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00:08:41,413 --> 00:08:44,758
Make sure the paper
Is aligned correctly.
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00:08:46,068 --> 00:08:48,862
At the machine's first station,
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00:08:48,862 --> 00:08:51,517
Tiny needles
Pierce holes in the paper
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00:08:51,517 --> 00:08:54,724
To enhance the quality
Of filtration.
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At the next station,
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A stamp imprints
The company logo in the paper.
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00:09:02,000 --> 00:09:05,448
A knife
Slices the paper in half,
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00:09:05,448 --> 00:09:07,896
Creating two
Side-by-side production lines
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From this point forward.
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00:09:10,103 --> 00:09:13,413
Each line
Enters a folding station,
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00:09:13,413 --> 00:09:18,275
Where guides fold the flat sheet
In half.
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00:09:18,275 --> 00:09:21,137
A roller embosses a seam
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00:09:21,137 --> 00:09:24,275
Connecting the two layers of
Paper along the bottom and side.
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00:09:24,275 --> 00:09:28,379
Then a second roller cuts
The conical shape of the filter.
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00:09:28,379 --> 00:09:33,517
The machine produces
4,000 filters per minute.
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00:09:33,517 --> 00:09:38,000
The next station
Cuts the filters apart
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00:09:38,000 --> 00:09:40,310
And collects the leftover paper,
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00:09:40,310 --> 00:09:42,931
Which will be recycled
Into pulp.
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00:09:45,862 --> 00:09:48,586
The filters are sent
To an automatic counting machine
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00:09:48,586 --> 00:09:52,586
That divides them
Into stacks of 80.
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The machine feeds the stacks
To the packaging line.
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00:10:04,206 --> 00:10:06,137
An automated packaging machine
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00:10:06,137 --> 00:10:08,793
Aligns each stack
With a flattened box.
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00:10:10,862 --> 00:10:14,758
Then it opens the box with a
Vacuum and inserts the filters.
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00:10:17,206 --> 00:10:20,103
If the machine's sensor
Detects a problem,
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00:10:20,103 --> 00:10:23,655
Like filters in the wrong
Position or missing filters,
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00:10:23,655 --> 00:10:26,586
It ejects that box
From the line.
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00:10:28,034 --> 00:10:32,172
This factory produces a few
Different types of filters.
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00:10:32,172 --> 00:10:35,517
How the cellulose
Is processed in the pulper
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Determines how the filter
Will perform.
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For example, the factory
Processes cellulose finely
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To make filters designed
To brew strong coffee.
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Fine cellulose produces paper
That drains slowly,
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00:10:49,758 --> 00:10:52,758
Keeping the water and
Coffee beans together longer,
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Resulting in a stronger flavor.
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Narrator:
Chainsaw mining machines
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Are among the largest
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00:11:08,896 --> 00:11:11,310
And heaviest chainsaws
In the world.
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00:11:11,310 --> 00:11:14,206
They're used in rock quarries
To cut and extract
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00:11:14,206 --> 00:11:16,689
Some of the toughest materials
On earth.
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00:11:16,689 --> 00:11:18,310
The machine's massive blade
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00:11:18,310 --> 00:11:21,413
Can make both vertical
And horizontal cuts,
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00:11:21,413 --> 00:11:23,896
Slicing through hard stone
As if it were butter.
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00:11:26,827 --> 00:11:30,827
Hundreds of feet underground,
This monster chainsaw
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00:11:30,827 --> 00:11:34,724
Is carving through
Geological deposits of marble.
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00:11:34,724 --> 00:11:38,724
The chainsaw arm can rotate
To make both horizontal
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00:11:38,724 --> 00:11:41,551
And vertical cuts as needed.
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00:11:44,551 --> 00:11:48,034
It cuts uniform blocks
Of marble.
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00:11:48,034 --> 00:11:53,137
Then a loader extracts
The blocks from the rock face.
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00:11:53,137 --> 00:11:57,655
They're the exact size
The customer requested,
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00:11:57,655 --> 00:11:59,655
Thanks to the precision
And power
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00:11:59,655 --> 00:12:01,896
Of the chainsaw mining machine.
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00:12:04,517 --> 00:12:07,551
It takes several steel tubes
Of various dimensions
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To make
A chainsaw mining machine.
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00:12:11,724 --> 00:12:17,241
They use an automated saw to cut
The tubes to the correct length.
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00:12:18,310 --> 00:12:21,206
This one will be used
For the chassis.
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00:12:27,241 --> 00:12:30,551
They assemble the tubes
In the correct configuration.
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00:12:30,551 --> 00:12:34,103
Then a worker joins them
With welds.
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00:12:34,103 --> 00:12:37,034
They lower the completed chassis
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00:12:37,034 --> 00:12:39,551
Onto
The chainsaw machine tracks.
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00:12:41,551 --> 00:12:46,068
The chassis is bolted
To the fifth-wheel coupling.
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00:12:46,068 --> 00:12:50,206
This allows the machine
To rotate 360 degrees.
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00:12:55,379 --> 00:12:58,137
They bring in the framework
That will house the motors,
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00:12:58,137 --> 00:13:00,896
Oil tank,
And electrical components.
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00:13:04,551 --> 00:13:06,793
They bolt the framework
To the chassis.
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00:13:08,827 --> 00:13:10,931
The next part is a rail system
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00:13:10,931 --> 00:13:14,034
For raising and lowering
The chainsaw blade.
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00:13:17,620 --> 00:13:20,206
A worker
Attaches the rail system
196
00:13:20,206 --> 00:13:22,827
To the chassis
Using a thick pin.
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00:13:22,827 --> 00:13:24,724
This pin acts as a hinge,
198
00:13:24,724 --> 00:13:31,206
Allowing the vertical structure
To be folded down when needed.
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00:13:33,000 --> 00:13:36,068
After verifying that
The machine's basic framework
200
00:13:36,068 --> 00:13:39,896
Fits together well,
They take it apart for painting.
201
00:13:39,896 --> 00:13:42,344
They also paint the gear motors.
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00:13:42,344 --> 00:13:44,827
This one will power the carriage
203
00:13:44,827 --> 00:13:47,379
That moves the blade back
And forth.
204
00:13:49,448 --> 00:13:51,379
Once all the parts
Have been painted,
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00:13:51,379 --> 00:13:53,896
They reassemble the framework.
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00:13:55,517 --> 00:13:58,931
Next, they mount the carriage
To the front of the machine.
207
00:13:58,931 --> 00:14:01,206
It rotates
Within the vertical rail
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00:14:01,206 --> 00:14:03,379
To position the blade
For cutting.
209
00:14:05,896 --> 00:14:07,896
Workers then install
The gear motor
210
00:14:07,896 --> 00:14:12,379
That powers the horizontal
Movement of the chainsaw blade.
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00:14:16,000 --> 00:14:18,724
They secure it
With several bolts.
212
00:14:22,655 --> 00:14:27,862
Two more gear motors
Will drive the cutting chain
213
00:14:27,862 --> 00:14:31,000
And rotate the blade.
214
00:14:36,034 --> 00:14:38,793
The team mounts them
To the front of the carriage,
215
00:14:38,793 --> 00:14:40,965
To the right
Of the other gear motor.
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00:14:43,000 --> 00:14:47,896
At the back of the carriage,
217
00:14:47,896 --> 00:14:50,482
A worker assembles a gear
Known as a pinion.
218
00:14:52,551 --> 00:14:56,827
The pinion engages
With a track called the rack.
219
00:14:59,137 --> 00:15:00,827
This rack-and-pinion system
220
00:15:00,827 --> 00:15:04,034
Allows the carriage
To slide back and forth.
221
00:15:07,068 --> 00:15:10,724
A worker folds hydraulic hoses
In a long metal cage
222
00:15:10,724 --> 00:15:14,206
And bolts the cage
To the front of the machine.
223
00:15:26,620 --> 00:15:28,517
Then he connects
The cutting-chain hoses
224
00:15:28,517 --> 00:15:29,793
To the motor,
225
00:15:29,793 --> 00:15:33,206
Protecting the connections
With metal half-flanges.
226
00:15:37,275 --> 00:15:42,896
They make all
The electrical connections...
227
00:15:46,551 --> 00:15:49,689
...Then screw fireproof
And waterproof covers
228
00:15:49,689 --> 00:15:51,551
Onto the electronics boxes.
229
00:15:55,241 --> 00:15:59,793
They program the chainsaw
Machine's operator screen.
230
00:15:59,793 --> 00:16:03,827
Stay tuned, because the big
Chainsaw blade is next.
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00:16:13,275 --> 00:16:15,379
Narrator:
Few things are as fierce
232
00:16:15,379 --> 00:16:18,827
As the blade of a stonecutting
Chainsaw machine.
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00:16:18,827 --> 00:16:22,310
It's 10 feet long,
Weighs over 1,300 pounds,
234
00:16:22,310 --> 00:16:23,931
And has big teeth
235
00:16:23,931 --> 00:16:27,965
That make cutting through
Solid rock look easy.
236
00:16:27,965 --> 00:16:30,034
It's no surprise that
Making one of these giant blades
237
00:16:30,034 --> 00:16:33,137
Is a huge job.
238
00:16:37,620 --> 00:16:41,379
A computer-driven plasma flame
Cuts a large blade
239
00:16:41,379 --> 00:16:44,379
From a sheet
Of high-carbon steel.
240
00:16:53,862 --> 00:16:56,448
Using a crane
With a powerful magnet,
241
00:16:56,448 --> 00:17:00,000
They transfer the chainsaw blade
To a milling station.
242
00:17:02,206 --> 00:17:06,000
Here, computerized tools
Smooth out the steel.
243
00:17:09,586 --> 00:17:12,379
They also bring the blade
To the correct width
244
00:17:12,379 --> 00:17:16,068
And carve channels
For lubrication tubes.
245
00:17:16,068 --> 00:17:19,206
They drill holes
For metal plates
246
00:17:19,206 --> 00:17:22,034
That will align
The cutting chain.
247
00:17:28,000 --> 00:17:31,896
The team paints the saw
And adds an attachment bar,
248
00:17:31,896 --> 00:17:35,379
Then mounts it to the front
Of the chainsaw machine.
249
00:17:36,758 --> 00:17:40,931
They slide the bar into
The blade support on the front.
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00:17:40,931 --> 00:17:44,000
It's a critical connection
Because it bears the weight
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00:17:44,000 --> 00:17:46,551
Of the heavy blade
As it saws through stone.
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00:17:50,344 --> 00:17:52,206
They secure it
To the blade support
253
00:17:52,206 --> 00:17:54,275
With a thick pin and a nut.
254
00:17:59,862 --> 00:18:03,103
Next, they make
The cutting-chain sprocket.
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00:18:03,103 --> 00:18:06,724
A computer-guided tool
Carves toothlike projections
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00:18:06,724 --> 00:18:10,206
Around the rim of a steel disk.
257
00:18:12,793 --> 00:18:18,000
These teeth are designed to grab
The links of the cutting chain.
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00:18:18,000 --> 00:18:21,137
The sprocket
Is ready to be mounted
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00:18:21,137 --> 00:18:23,206
To the chainsaw machine.
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00:18:25,896 --> 00:18:29,034
An employee slides the sprocket
Onto a shaft
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00:18:29,034 --> 00:18:32,206
Protruding from
The cutting-chain gear motor.
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00:18:32,206 --> 00:18:35,931
He bolts the disk
To the surrounding hub.
263
00:18:38,000 --> 00:18:43,241
Next,
They assemble the cutting chain.
264
00:18:43,241 --> 00:18:49,206
A two-part fastener system
Holds the links together.
265
00:18:49,206 --> 00:18:52,137
It starts with this hollow pin.
266
00:18:52,137 --> 00:18:55,965
A worker drives the hollow pin
Into a hole in the links
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00:18:55,965 --> 00:18:59,241
Using a hydraulic press.
268
00:18:59,241 --> 00:19:02,724
He inserts an l-shaped pin
Into the hollow pin.
269
00:19:02,724 --> 00:19:05,379
The tongue of the l-shaped pin
Fits into a groove
270
00:19:05,379 --> 00:19:07,896
Adjacent to the hollow pin.
271
00:19:09,241 --> 00:19:13,896
The press forces the
L-shaped pin into the groove.
272
00:19:15,034 --> 00:19:17,724
He alternates outer links
And inner ones
273
00:19:17,724 --> 00:19:21,482
To build a 30-foot chain
That will fit to the saw body.
274
00:19:21,482 --> 00:19:24,862
Then another worker
Loops it around the saw blade
275
00:19:24,862 --> 00:19:27,655
And sprocket.
276
00:19:31,586 --> 00:19:34,206
The chain fits perfectly
To the saw.
277
00:19:37,172 --> 00:19:41,275
He joins the ends of the chain
With a hollow pin
278
00:19:41,275 --> 00:19:45,379
And an l-shaped pin
To complete the loop.
279
00:19:46,793 --> 00:19:49,931
He flattens them
With a hammer instead of a press
280
00:19:49,931 --> 00:19:53,655
Because it's easier
To use a hammer at this angle.
281
00:19:53,655 --> 00:19:55,344
The chain is in place,
282
00:19:55,344 --> 00:19:59,310
But it doesn't have the teeth
It needs to cut stone yet.
283
00:19:59,310 --> 00:20:03,379
These parts, a carrier and
A tungsten carbide cutting bit,
284
00:20:03,379 --> 00:20:07,896
Give the blade its cutting edge.
285
00:20:09,551 --> 00:20:13,034
He places a set on each
Of the chain's outer links...
286
00:20:15,586 --> 00:20:17,551
...Then screws them in.
287
00:20:23,206 --> 00:20:25,517
Studded with tough, sharp teeth,
288
00:20:25,517 --> 00:20:29,586
This mega chainsaw is now ready
For rock-cutting action.
289
00:20:29,586 --> 00:20:34,034
It cuts through stone cleanly
And efficiently.
290
00:20:35,862 --> 00:20:37,620
Its size and power
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00:20:37,620 --> 00:20:41,896
Make it a force
To be reckoned with underground.
292
00:20:44,206 --> 00:20:46,586
Despite its bulky frame,
293
00:20:46,586 --> 00:20:51,551
This chainsaw mining machine
Has a wide range of motion.
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00:20:51,551 --> 00:20:55,344
Here, the front carriage
Rotates the blade
295
00:20:55,344 --> 00:21:00,310
To demonstrate how it can be
Repositioned between cuts.
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00:21:02,896 --> 00:21:11,379
No matter how you slice it...
That's pretty impressive.
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00:21:19,344 --> 00:21:21,586
If you have any comments
About the show,
298
00:21:21,586 --> 00:21:24,379
Or if you'd like to suggest
Topics for future shows,
299
00:21:24,379 --> 00:21:26,482
Drop us a line at...
24505
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