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00:00:03,104 --> 00:00:05,871
NARRATOR:
Underneath the streets
of London,
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00:00:05,873 --> 00:00:08,907
an army of more than
10,000 engineers
3
00:00:08,909 --> 00:00:12,211
is building a brand new
subterranean railway.
4
00:00:13,581 --> 00:00:14,613
Okay!
5
00:00:14,615 --> 00:00:15,714
MAN:
We've done the maths,
6
00:00:15,716 --> 00:00:16,949
we've checked the maths,
7
00:00:16,951 --> 00:00:18,317
and we've checked them
a third time.
8
00:00:18,319 --> 00:00:22,254
NARRATOR:
Costing almost $23 billion,
9
00:00:22,256 --> 00:00:26,125
it's the biggest
construction project in Europe.
10
00:00:26,127 --> 00:00:27,860
I've been doing civil
engineering for 35 or so years.
11
00:00:27,862 --> 00:00:29,561
Even I can't appreciate
the scale
12
00:00:29,563 --> 00:00:31,497
until I come down here.
13
00:00:31,499 --> 00:00:34,733
NARRATOR:
Workers are digging
26 miles of tunnels
14
00:00:34,735 --> 00:00:38,203
and constructing ten
vast new stations
15
00:00:38,205 --> 00:00:40,639
all under a tight deadline.
16
00:00:40,641 --> 00:00:43,942
WOMAN:
You need to get
out of the way here,
17
00:00:43,944 --> 00:00:45,978
because trains are gonna start
coming through.
18
00:00:48,783 --> 00:00:53,185
NARRATOR:
They're over halfway through
a ten-year project.
19
00:00:53,187 --> 00:00:54,520
That's ready to start pumping!
20
00:00:54,522 --> 00:00:58,524
NARRATOR:
In a constant battle
to keep the city moving.
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00:00:58,526 --> 00:01:01,427
MAN:
Constructing Crossrail is like
undertaking open-heart surgery
22
00:01:01,429 --> 00:01:04,630
on a patient
whilst that patient is awake.
23
00:01:04,632 --> 00:01:09,435
NARRATOR:
The oldest rapid transit system
in the world,
24
00:01:09,437 --> 00:01:15,074
the famed London Underground
is growing even bigger:
25
00:01:15,076 --> 00:01:17,543
75 new miles of railway
26
00:01:17,545 --> 00:01:20,979
in the midst of a city
that never stops.
27
00:01:20,981 --> 00:01:25,584
Inside the "Super Tunnel,"
right now on NOVA.
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00:01:40,901 --> 00:01:44,503
Major funding for NOVA is
provided by the following...
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00:01:46,073 --> 00:01:47,239
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for large blaze?
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00:01:47,241 --> 00:01:48,240
Fire.
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00:01:48,242 --> 00:01:49,475
13 letters.
32
00:01:49,477 --> 00:01:50,476
Fire!
33
00:01:50,478 --> 00:01:51,477
13 letters.
34
00:01:51,479 --> 00:01:53,212
Really big fire.
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00:01:53,214 --> 00:01:54,780
Conflagration--
seen it, covered it.
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We know a thing or two because
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care that never quits.
47
00:02:18,339 --> 00:02:22,107
Supporting NOVA and promoting
public understanding of science.
48
00:02:25,279 --> 00:02:28,480
And the Corporation
for Public Broadcasting.
49
00:02:28,482 --> 00:02:32,117
And by PBS viewers like you.
Thank you.
50
00:02:32,119 --> 00:02:34,720
Additional funding is provided
51
00:02:34,722 --> 00:02:37,556
by The Montgomery Family
Foundation.
52
00:02:43,230 --> 00:02:48,167
ople.
53
00:02:50,171 --> 00:02:54,907
The key to keeping
everyone moving: the Tube.
54
00:02:57,144 --> 00:03:02,047
The London Underground was
the world's first metro system,
55
00:03:02,049 --> 00:03:06,518
a vast subterranean rail network
56
00:03:06,520 --> 00:03:11,256
handling over a billion journeys
a year.
57
00:03:11,258 --> 00:03:14,826
It's made up of ten
separate railway lines
58
00:03:14,828 --> 00:03:17,629
that snake
right underneath the city.
59
00:03:17,631 --> 00:03:21,967
A network of escalators
and walkways allow commuters
60
00:03:21,969 --> 00:03:25,137
to disembark from one line
and board another
61
00:03:25,139 --> 00:03:28,307
to travel in any direction
across the capital.
62
00:03:36,650 --> 00:03:41,153
Victorian engineers opened
the first line here in 1863
63
00:03:41,155 --> 00:03:46,525
at an estimated cost
of a million pounds.
64
00:03:46,527 --> 00:03:50,028
It was built to solve
what was, even then,
65
00:03:50,030 --> 00:03:53,565
London's massive
traffic problem.
66
00:03:55,970 --> 00:03:58,537
To build it, engineers
closed streets for years,
67
00:03:58,539 --> 00:04:02,541
cutting huge trenches,
laying track,
68
00:04:02,543 --> 00:04:05,077
then covering the holes
back up again.
69
00:04:08,482 --> 00:04:12,551
Today, the traffic in London
has gotten even worse.
70
00:04:12,553 --> 00:04:13,685
(horn honking)
71
00:04:13,687 --> 00:04:15,020
CABBIE:
You just gotta keep your cool
72
00:04:15,022 --> 00:04:16,521
and just go with the flow,
73
00:04:16,523 --> 00:04:18,824
not get too stressed out
about it all,
74
00:04:18,826 --> 00:04:20,559
because you'll just
drive yourself mad.
75
00:04:20,561 --> 00:04:21,860
(horn honking)
76
00:04:23,097 --> 00:04:25,964
NARRATOR:
This makes the Tube
even more important--
77
00:04:25,966 --> 00:04:27,532
and crowded.
78
00:04:31,171 --> 00:04:34,339
The 150-year-old network
79
00:04:34,341 --> 00:04:37,509
struggles to cope
with peak demand.
80
00:04:40,981 --> 00:04:43,482
So today, engineers
are building
81
00:04:43,484 --> 00:04:46,718
a brand-new underground
railway line
82
00:04:46,720 --> 00:04:49,154
to help relieve the strain.
83
00:04:49,156 --> 00:04:51,757
It will stretch
right across the city,
84
00:04:51,759 --> 00:04:53,725
from the east to the west.
85
00:04:53,727 --> 00:04:56,628
It's called Crossrail.
86
00:04:58,532 --> 00:05:00,632
It will run overground
87
00:05:00,634 --> 00:05:03,168
from Heathrow Airport
in the west
88
00:05:03,170 --> 00:05:07,239
in a new tunnel
under Central London
89
00:05:07,241 --> 00:05:09,908
connecting into existing
metro stations.
90
00:05:09,910 --> 00:05:12,010
It will link shopping
and theater districts
91
00:05:12,012 --> 00:05:13,645
in the West End
92
00:05:13,647 --> 00:05:17,749
to the new financial district
of Canary Wharf
93
00:05:17,751 --> 00:05:21,553
and terminate 14 miles east
of the city center.
94
00:05:21,555 --> 00:05:24,823
It must link seamlessly
to the rest of the Tube
95
00:05:24,825 --> 00:05:29,961
and be ready for passengers
in 2018.
96
00:05:29,963 --> 00:05:35,434
If all goes well, Heathrow,
Europe's busiest airport,
97
00:05:35,436 --> 00:05:38,437
will be just 28 minutes
from London's West End,
98
00:05:38,439 --> 00:05:42,774
a journey that currently takes
almost an hour on the Tube.
99
00:05:42,776 --> 00:05:46,845
An idea born in 1974,
100
00:05:46,847 --> 00:05:51,183
Crossrail is now the biggest
engineering project in Europe.
101
00:05:53,087 --> 00:05:55,320
Building Crossrail
in the middle of nowhere
102
00:05:55,322 --> 00:05:58,156
would be a big enough technical
challenge, but to do that
103
00:05:58,158 --> 00:05:59,758
right in the center of London
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00:05:59,760 --> 00:06:01,393
with all of the neighbors
above us and around us
105
00:06:01,395 --> 00:06:05,197
makes it more complex still.
106
00:06:05,199 --> 00:06:10,268
NARRATOR:
Today, there are 40 worksites
spread out across London.
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00:06:14,341 --> 00:06:17,476
Some are little more than shafts
allowing access
108
00:06:17,478 --> 00:06:20,145
to the new train tunnels
growing underground.
109
00:06:20,147 --> 00:06:23,448
Others are giant holes
puncturing the landscape,
110
00:06:23,450 --> 00:06:26,518
forming the outlines
of ten new stations.
111
00:06:29,423 --> 00:06:30,889
The sites in Central London
are hemmed in
112
00:06:30,891 --> 00:06:33,325
between office buildings,
busy shops,
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00:06:33,327 --> 00:06:35,260
and heavily congested roads.
114
00:06:37,398 --> 00:06:39,131
And that's just at street level.
115
00:06:42,169 --> 00:06:46,438
Things get even tighter
underground.
116
00:06:49,510 --> 00:06:52,411
This is Oxford Street,
117
00:06:52,413 --> 00:06:55,847
the heart of the London
shopping district.
118
00:06:57,985 --> 00:07:01,219
It's the busiest
commercial street in Europe.
119
00:07:02,823 --> 00:07:04,156
Home to flagship stores
120
00:07:04,158 --> 00:07:07,859
including the legendary
Selfridges department store,
121
00:07:07,861 --> 00:07:12,164
200 million people visit
Oxford Street each year.
122
00:07:14,468 --> 00:07:17,502
Few shoppers here
would ever suspect
123
00:07:17,504 --> 00:07:19,237
that just 80 feet below,
124
00:07:19,239 --> 00:07:22,641
a 500-member team
of engineers and builders
125
00:07:22,643 --> 00:07:25,377
is chewing through the earth.
126
00:07:25,379 --> 00:07:27,913
Tunnel construction manager
Steve Parker
127
00:07:27,915 --> 00:07:30,148
keeps the project moving,
128
00:07:30,150 --> 00:07:34,753
hopefully without disrupting
life on the street above.
129
00:07:34,755 --> 00:07:37,956
PARKER:
In the future, I want to be
taking my family in this tunnel
130
00:07:37,958 --> 00:07:40,325
and say,
"Look, I worked on this."
131
00:07:40,327 --> 00:07:42,394
I think many tunnelers
like to think of themselves
132
00:07:42,396 --> 00:07:44,629
as kind of the unsung heroes
133
00:07:44,631 --> 00:07:47,199
because it's all underground.
134
00:07:47,201 --> 00:07:51,636
NARRATOR:
Steve has been building tunnels
for over 25 years.
135
00:07:51,638 --> 00:07:53,638
He started out as
a construction worker,
136
00:07:53,640 --> 00:07:56,475
but now oversees the operation
137
00:07:56,477 --> 00:08:00,846
of two giant tunnel boring
machines, called TBMs.
138
00:08:05,285 --> 00:08:09,521
In all, there are eight of these
dirt-eating monsters.
139
00:08:09,523 --> 00:08:16,161
Each one is 490 feet long
and weighs 1,000 tons.
140
00:08:17,831 --> 00:08:19,464
The machines have been
boring away
141
00:08:19,466 --> 00:08:22,734
for just over a year,
but now Steve's crew
142
00:08:22,736 --> 00:08:26,638
is about to face
its toughest challenge yet.
143
00:08:26,640 --> 00:08:32,077
The brand new tunnel
and ten new Crossrail stations
144
00:08:32,079 --> 00:08:36,481
must connect into the existing
London Underground network.
145
00:08:36,483 --> 00:08:39,384
This means
the tunnel boring machine
146
00:08:39,386 --> 00:08:42,988
must drive dangerously close
to tunnels and other structures.
147
00:08:45,025 --> 00:08:49,594
But only once
will they pass this close.
148
00:08:49,596 --> 00:08:52,264
Engineers prepare to inch
one of the tunneling machines
149
00:08:52,266 --> 00:08:56,067
through the tightest point
of the entire route,
150
00:08:56,069 --> 00:09:00,105
known as
"The Eye of the Needle."
151
00:09:00,107 --> 00:09:02,841
At the east end
of Oxford Street
152
00:09:02,843 --> 00:09:08,480
lies London Underground's
Tottenham Court Road Station.
153
00:09:08,482 --> 00:09:12,250
Crossrail's new tunnel
and station here
154
00:09:12,252 --> 00:09:15,453
will link into two
existing Tube lines
155
00:09:15,455 --> 00:09:18,857
called the Northern Line
and Central Line,
156
00:09:18,859 --> 00:09:23,528
creating a Central London
super hub.
157
00:09:23,530 --> 00:09:26,865
But digging tunnels here
is not easy.
158
00:09:26,867 --> 00:09:31,803
Pipes, cables, and sewers
crowd the ground.
159
00:09:31,805 --> 00:09:36,241
The Tube's busy Northern Line
platforms and two escalators
160
00:09:36,243 --> 00:09:38,577
make the earth
extremely crowded.
161
00:09:41,048 --> 00:09:43,882
The only option for Steve's team
is to drive
162
00:09:43,884 --> 00:09:47,352
their tunneling machine
through the tightest of gaps,
163
00:09:47,354 --> 00:09:51,957
33 inches above the live,
running Northern Line
164
00:09:51,959 --> 00:09:55,460
and 14 inches
below the escalators.
165
00:09:58,398 --> 00:10:01,433
It's the closest
any Crossrail tunnel will come
166
00:10:01,435 --> 00:10:07,539
to the critical infrastructure
that keeps London ticking.
167
00:10:07,541 --> 00:10:09,674
At the controls for
the tightest drive of them all
168
00:10:09,676 --> 00:10:11,376
is engineer Ed Batty.
169
00:10:13,180 --> 00:10:15,413
We've been in tricky spots
before,
170
00:10:15,415 --> 00:10:19,017
but nothing where we've had
something below us and above us
171
00:10:19,019 --> 00:10:23,388
in such a close proximity,
so yeah, it's a first for me.
172
00:10:23,390 --> 00:10:25,323
My first job on a TBM,
173
00:10:25,325 --> 00:10:28,059
and this is one year and
one month I've been down here.
174
00:10:28,061 --> 00:10:29,961
The first six months was
a learning curve,
175
00:10:29,963 --> 00:10:33,698
and now I know
what the crack is, basically.
176
00:10:41,008 --> 00:10:43,742
NARRATOR:
Steve and the team
have a crucial meeting
177
00:10:43,744 --> 00:10:47,612
with London Underground
to coordinate their next step:
178
00:10:47,614 --> 00:10:51,216
how to avoid interrupting
Tube services.
179
00:10:53,487 --> 00:10:55,420
MAN:
C'mon!
180
00:10:55,422 --> 00:10:57,922
NARRATOR:
The tunnelers can't cause
any interruption
181
00:10:57,924 --> 00:11:00,258
during the 48 hours
it will take their machine
182
00:11:00,260 --> 00:11:02,961
to pass through
the Eye of the Needle.
183
00:11:02,963 --> 00:11:04,462
The tunnel boring machine
184
00:11:04,464 --> 00:11:06,297
is passing directly
over a platform tunnel,
185
00:11:06,299 --> 00:11:07,832
so our customers
will be able to see
186
00:11:07,834 --> 00:11:11,202
the impact of the tunnel boring
machine passing by.
187
00:11:11,204 --> 00:11:13,038
For example, you could have
tiles falling off.
188
00:11:13,040 --> 00:11:15,006
If we had customers
on the platform
189
00:11:15,008 --> 00:11:16,741
who started seeing
a lot of fluid come in,
190
00:11:16,743 --> 00:11:18,476
they might cause a panic.
191
00:11:18,478 --> 00:11:20,178
If the worst comes to the worst,
192
00:11:20,180 --> 00:11:21,913
we might have to evacuate
the station.
193
00:11:23,517 --> 00:11:25,283
The only thing we've got
to bottom out
194
00:11:25,285 --> 00:11:27,018
is what surveillance regime
we're going to have in place.
195
00:11:27,020 --> 00:11:30,221
NARRATOR:
The team must keep a close eye
on the Tube platform
196
00:11:30,223 --> 00:11:33,558
while the machine passes
overhead.
197
00:11:33,560 --> 00:11:36,528
They will have just seconds
to halt the operation
198
00:11:36,530 --> 00:11:38,063
should a crack appear.
199
00:11:38,065 --> 00:11:40,231
PEARCE:
I suppose the real excitement,
200
00:11:40,233 --> 00:11:42,500
if you like,
or the adrenaline will start
201
00:11:42,502 --> 00:11:44,269
if there is an incident.
202
00:11:46,773 --> 00:11:49,674
NARRATOR:
If all goes well here,
trains and people
203
00:11:49,676 --> 00:11:53,745
passing through this station
won't miss a beat.
204
00:11:53,747 --> 00:11:57,348
But if any of the other
construction sites
205
00:11:57,350 --> 00:11:58,883
fall behind schedule,
206
00:11:58,885 --> 00:12:03,655
the entire $23 billion project
could be derailed.
207
00:12:10,263 --> 00:12:12,897
One site that could easily
become a problem
208
00:12:12,899 --> 00:12:15,900
is the new Crossrail station
at Canary Wharf,
209
00:12:15,902 --> 00:12:17,969
London's financial hub.
210
00:12:22,409 --> 00:12:27,245
Here, workers are building
an utterly unique structure.
211
00:12:28,982 --> 00:12:34,385
Since the 1980s, Canary Wharf
has been transformed
212
00:12:34,387 --> 00:12:37,188
from a derelict
post-industrial wasteland
213
00:12:37,190 --> 00:12:40,225
into the Wall Street of London,
214
00:12:40,227 --> 00:12:44,062
home to many of Europe's
tallest buildings.
215
00:12:44,064 --> 00:12:46,264
Over 100,000 people now work
216
00:12:46,266 --> 00:12:48,166
in this booming
financial jungle,
217
00:12:48,168 --> 00:12:52,036
so the area needs
better transportation links
218
00:12:52,038 --> 00:12:54,272
to help get them all there.
219
00:12:54,274 --> 00:13:00,245
At 1,050 feet long, Crossrail's
Canary Wharf Station is vast,
220
00:13:00,247 --> 00:13:03,681
as long as three-and-a-half
football fields.
221
00:13:03,683 --> 00:13:06,918
But because space around
the docks is at a premium,
222
00:13:06,920 --> 00:13:10,421
they had to build it underwater.
223
00:13:10,423 --> 00:13:13,124
To do so, they sank
224
00:13:13,126 --> 00:13:16,828
an 840-foot-long watertight
concrete box
225
00:13:16,830 --> 00:13:18,730
to form the station's walls.
226
00:13:20,667 --> 00:13:24,335
Concrete pillars anchor it
into the dock bed.
227
00:13:24,337 --> 00:13:28,573
They drained out more than 40
Olympic swimming pools of water,
228
00:13:28,575 --> 00:13:31,476
then dug down to create
229
00:13:31,478 --> 00:13:34,979
four additional floors
below water level
230
00:13:34,981 --> 00:13:38,049
and built two floors above.
231
00:13:38,051 --> 00:13:41,319
To transform this concrete box
into a station,
232
00:13:41,321 --> 00:13:44,022
first they must build
the platforms,
233
00:13:44,024 --> 00:13:47,492
then install the escalators.
234
00:13:47,494 --> 00:13:49,761
But that's a walk in the park
235
00:13:49,763 --> 00:13:52,497
compared to assembling
its intricate roof
236
00:13:52,499 --> 00:13:55,333
from 1,500 timber beams
237
00:13:55,335 --> 00:13:59,337
to house a public garden
open 24 hours a day.
238
00:14:01,241 --> 00:14:04,209
This ambitious
thousand-ton canopy
239
00:14:04,211 --> 00:14:07,412
will be built from specially
engineered timber beams
240
00:14:07,414 --> 00:14:09,614
manufactured in Austria,
241
00:14:09,616 --> 00:14:14,886
joined together using
860 steel connectors.
242
00:14:14,888 --> 00:14:20,558
The wooden frame will be covered
by air-filled plastic panels,
243
00:14:20,560 --> 00:14:22,493
enclosing the rooftop garden.
244
00:14:25,232 --> 00:14:28,333
Overseeing the German
construction workers
245
00:14:28,335 --> 00:14:31,202
who have six months to assemble
this giant 3-D puzzle...
246
00:14:34,007 --> 00:14:35,106
NARRATOR:
...is Phil Duffy.
247
00:14:38,879 --> 00:14:40,945
One or two of our lads
don't speak much English,
248
00:14:40,947 --> 00:14:43,348
so it helps a little bit
to be able to speak a small bit.
249
00:14:46,686 --> 00:14:51,623
(speaking German)
250
00:14:58,231 --> 00:14:59,430
Okay, Prem,
251
00:14:59,432 --> 00:15:01,399
up on one on the hoist,
up on one.
252
00:15:03,436 --> 00:15:06,471
NARRATOR:
Phil's first milestone:
253
00:15:06,473 --> 00:15:08,840
assemble the first arch
of the canopy.
254
00:15:10,010 --> 00:15:11,509
If we don't have these
in the exact right position,
255
00:15:11,511 --> 00:15:12,944
the timber elements won't fit.
256
00:15:12,946 --> 00:15:14,646
Tiny bit down?
257
00:15:14,648 --> 00:15:16,247
DUFFY:
Everything has to be
258
00:15:16,249 --> 00:15:17,148
within the millimeter.
259
00:15:17,150 --> 00:15:19,450
This is like the keystone.
260
00:15:19,452 --> 00:15:20,785
The big crane will lift this in,
261
00:15:20,787 --> 00:15:23,521
and hopefully then
it will slot in
262
00:15:23,523 --> 00:15:24,889
to the exact right position.
263
00:15:24,891 --> 00:15:27,458
If this aligns up, the whole
structure will follow through,
264
00:15:27,460 --> 00:15:29,761
so this will be one
of the most critical lifts
265
00:15:29,763 --> 00:15:31,963
of the whole thing.
266
00:15:35,568 --> 00:15:38,503
Have you got a knife on that
little Swiss thing of yours?
267
00:15:38,505 --> 00:15:39,671
It's for nails, but...
268
00:15:41,474 --> 00:15:45,376
NARRATOR:
The first arch needs a keystone,
a two-ton timber unit
269
00:15:45,378 --> 00:15:48,880
that will hold
the structure together.
270
00:15:48,882 --> 00:15:51,716
RAY PALLETT:
We're just about to put
the center section in place
271
00:15:51,718 --> 00:15:53,418
using the tower crane.
272
00:15:53,420 --> 00:15:55,687
We'll get everybody else
out of the way,
273
00:15:55,689 --> 00:15:57,088
and hopefully it will go well.
274
00:15:59,192 --> 00:16:00,858
As you slew round, mate,
275
00:16:00,860 --> 00:16:02,226
that should stay
same orientation.
276
00:16:03,964 --> 00:16:05,296
Heads up, heads up!
277
00:16:12,205 --> 00:16:14,639
Nice and steady,
inches at a time, please, mate,
278
00:16:14,641 --> 00:16:16,541
nice and steady,
come down on your wire.
279
00:16:18,678 --> 00:16:23,715
NARRATOR:
The keystone is in position,
but it's not a perfect fit.
280
00:16:23,717 --> 00:16:26,184
Just trying to locate the bolts
on each corner.
281
00:16:28,321 --> 00:16:29,921
It's literally millimeters out.
282
00:16:29,923 --> 00:16:32,357
If we have an issue here at one
of these timber structures here,
283
00:16:32,359 --> 00:16:35,693
it means it exaggerates
as you go along the building
284
00:16:35,695 --> 00:16:37,929
and our connections
won't go in correctly.
285
00:16:37,931 --> 00:16:40,098
For alignment,
they have to be perfect,
286
00:16:40,100 --> 00:16:42,500
within maybe five mill.
287
00:16:42,502 --> 00:16:47,038
NARRATOR:
So they apply
a bit of brute force.
288
00:16:47,040 --> 00:16:48,439
PALLETT:
Hit it properly, Robin!
289
00:16:48,441 --> 00:16:49,607
(laughs)
290
00:16:51,311 --> 00:16:53,778
You can't beat the sledgehammer
at the end of the day.
291
00:16:53,780 --> 00:16:54,879
(laughing)
292
00:17:05,392 --> 00:17:07,558
Yeah, that's it.
293
00:17:07,560 --> 00:17:08,760
Fairly chuffed, yeah.
294
00:17:10,864 --> 00:17:12,864
Oh yeah, I think I should have
been a photographer.
295
00:17:12,866 --> 00:17:14,866
What do you think?
296
00:17:14,868 --> 00:17:16,300
If you stand back
and look at it,
297
00:17:16,302 --> 00:17:17,735
you can see the whole arch
298
00:17:17,737 --> 00:17:19,003
from one side
to the other side now,
299
00:17:19,005 --> 00:17:20,004
which is perfect.
300
00:17:20,006 --> 00:17:22,340
This is a massive structure,
like,
301
00:17:22,342 --> 00:17:24,642
and when it goes to plan,
you can't be happier.
302
00:17:24,644 --> 00:17:26,911
Looking more than good,
looking brilliant.
303
00:17:26,913 --> 00:17:28,546
NARRATOR:
First milestone complete.
304
00:17:28,548 --> 00:17:30,548
Okay!
305
00:17:30,550 --> 00:17:34,218
NARRATOR:
They are on schedule for now,
306
00:17:34,220 --> 00:17:37,388
but there are 1,300 pieces
of the puzzle to go.
307
00:17:42,262 --> 00:17:44,729
And the station is only
five short miles
308
00:17:44,731 --> 00:17:47,165
from Tottenham Court Road
and London's shopping district.
309
00:17:50,970 --> 00:17:55,239
Already a large station,
it's growing further,
310
00:17:55,241 --> 00:17:58,676
adding a network of underground
walkways and escalators
311
00:17:58,678 --> 00:18:02,680
to connect it to Crossrail's
new tunnel and platform.
312
00:18:02,682 --> 00:18:06,751
When completed, it will become
a greatly expanded gateway
313
00:18:06,753 --> 00:18:08,052
to the shops above.
314
00:18:15,762 --> 00:18:17,829
Just off the main thoroughfare
315
00:18:17,831 --> 00:18:23,501
is the 335-year-old oasis
of Soho Square.
316
00:18:23,503 --> 00:18:24,936
Crossrail is building
a new station
317
00:18:24,938 --> 00:18:26,270
directly underneath
our feet here.
318
00:18:26,272 --> 00:18:28,673
Our tunnel boring machine
is directly under this building
319
00:18:28,675 --> 00:18:30,341
opposite us there.
320
00:18:32,178 --> 00:18:35,513
NARRATOR:
Advancing on average
72 feet a day,
321
00:18:35,515 --> 00:18:38,549
Crossrail's vast
tunnel boring machine
322
00:18:38,551 --> 00:18:41,919
is closing in
on the Eye of the Needle.
323
00:18:44,224 --> 00:18:47,458
The Tunnel Boring Machine,
or TBM,
324
00:18:47,460 --> 00:18:50,595
has sharp cutters
in a huge rotating wheel
325
00:18:50,597 --> 00:18:54,098
that scrape at the earth
like a drill.
326
00:18:54,100 --> 00:18:58,035
Behind this cutter head is
an enclosed steel jacket
327
00:18:58,037 --> 00:19:00,004
that holds the earth at bay
328
00:19:00,006 --> 00:19:03,241
and creates a safe area
for the tunnelers.
329
00:19:03,243 --> 00:19:06,043
Eight pre-cast segments
make up each ring,
330
00:19:06,045 --> 00:19:09,313
and workers secure them
with bolts.
331
00:19:13,820 --> 00:19:15,686
Once a ring is complete,
332
00:19:15,688 --> 00:19:20,124
hydraulic rams push the machine
further forward into the ground.
333
00:19:22,195 --> 00:19:24,295
Every five feet they advance
334
00:19:24,297 --> 00:19:27,965
creates space
to build another ring.
335
00:19:27,967 --> 00:19:30,001
In perfect conditions,
336
00:19:30,003 --> 00:19:34,105
this digging demon can build
up to 45 rings a day,
337
00:19:34,107 --> 00:19:37,308
leaving a water-tight,
tube-shaped train tunnel
338
00:19:37,310 --> 00:19:38,442
in its wake.
339
00:19:43,550 --> 00:19:44,882
ALDER:
We've got to pass
under a couple of buildings
340
00:19:44,884 --> 00:19:47,318
before it gets
to the Eye of the Needle,
341
00:19:47,320 --> 00:19:48,653
but before we get there,
342
00:19:48,655 --> 00:19:50,087
obviously we've got to protect
the buildings.
343
00:19:50,089 --> 00:19:52,190
We don't want to put
the table tennis table
344
00:19:52,192 --> 00:19:53,457
out of level.
345
00:19:55,862 --> 00:19:58,129
It's all part
of keeping London moving.
346
00:20:01,334 --> 00:20:05,102
NARRATOR:
Digging directly under a city is
a delicate operation.
347
00:20:05,104 --> 00:20:08,606
The loose ground
around freshly-dug tunnels
348
00:20:08,608 --> 00:20:11,075
could settle unevenly,
349
00:20:11,077 --> 00:20:14,679
potentially tilting
and damaging buildings.
350
00:20:14,681 --> 00:20:19,217
So Crossrail's engineers use
a network of lasers and targets,
351
00:20:19,219 --> 00:20:22,153
capable of registering
even a millimeter of movement
352
00:20:22,155 --> 00:20:24,488
in any of the buildings.
353
00:20:24,490 --> 00:20:26,824
ALDER:
If you look closely
on the buildings,
354
00:20:26,826 --> 00:20:28,192
you can see lines
of these prisms
355
00:20:28,194 --> 00:20:29,660
that are all across the facades.
356
00:20:29,662 --> 00:20:30,661
On the far corner there
357
00:20:30,663 --> 00:20:32,964
on the brackets
away from the building,
358
00:20:32,966 --> 00:20:35,299
you can see an automatic station
up on the end there.
359
00:20:35,301 --> 00:20:37,068
It will know where these prisms
are supposed to be,
360
00:20:37,070 --> 00:20:39,237
it'll turn the instrument
361
00:20:39,239 --> 00:20:42,106
to see where it last read
the prism from,
362
00:20:42,108 --> 00:20:43,608
and then it will take the shot
that will give it
363
00:20:43,610 --> 00:20:45,109
the exact location of the prism.
364
00:20:45,111 --> 00:20:46,877
You'll see it rotating
round now,
365
00:20:46,879 --> 00:20:48,713
working its way around,
366
00:20:48,715 --> 00:20:51,482
and then sending all that data
back to the control room
367
00:20:51,484 --> 00:20:53,985
so we know where all these
prisms are in real time.
368
00:20:56,422 --> 00:21:00,625
NARRATOR:
Data from thousands of targets
installed across Central London
369
00:21:00,627 --> 00:21:03,728
flows back to Tunnel Control.
370
00:21:03,730 --> 00:21:08,499
Here, Simon Leavy specializes
in the analysis of this data,
371
00:21:08,501 --> 00:21:13,404
picking up the slightest change
in ground level.
372
00:21:13,406 --> 00:21:16,440
If the ground moves
either up or down,
373
00:21:16,442 --> 00:21:18,542
we can tell from these graphs.
374
00:21:18,544 --> 00:21:20,778
The nodes on the points
are blue,
375
00:21:20,780 --> 00:21:22,713
so that means they're not
in any trigger area,
376
00:21:22,715 --> 00:21:24,482
but if they go to a green,
377
00:21:24,484 --> 00:21:27,418
it's a green alert,
amber and red.
378
00:21:30,556 --> 00:21:33,190
NARRATOR:
Robot trackers keep an eye
379
00:21:33,192 --> 00:21:36,661
on some of the oldest buildings
in London 24 hours a day.
380
00:21:38,331 --> 00:21:41,132
Among them is one of
the most celebrated structures
381
00:21:41,134 --> 00:21:43,567
next to Oxford Street,
in historic Soho Square:
382
00:21:43,569 --> 00:21:48,439
the mid-18th century charity
and chapel
383
00:21:48,441 --> 00:21:49,974
House of St. Barnabas.
384
00:21:52,111 --> 00:21:57,448
MAN:
This is the plasterwork
installed in 1754.
385
00:21:57,450 --> 00:21:59,583
It's a classic piece
of Rococo work.
386
00:21:59,585 --> 00:22:02,486
The main hall
387
00:22:02,488 --> 00:22:05,156
and the Silk Room next door
388
00:22:05,158 --> 00:22:07,892
together constitute
the last complete set
389
00:22:07,894 --> 00:22:10,061
of Rococo plasterwork in London.
390
00:22:12,632 --> 00:22:15,666
NARRATOR:
This building is
under constant surveillance.
391
00:22:15,668 --> 00:22:17,802
A steel frame
stands ready to catch
392
00:22:17,804 --> 00:22:21,305
the 260-year-old staircase,
should it collapse.
393
00:22:24,277 --> 00:22:28,312
The House of St. Barnabas
is bristling with instruments.
394
00:22:28,314 --> 00:22:30,681
But despite steps taken
395
00:22:30,683 --> 00:22:32,917
to support its stairway
and protect its pillars,
396
00:22:32,919 --> 00:22:36,120
there's still a risk.
397
00:22:40,760 --> 00:22:44,328
As workers dig
beneath Soho Square...
398
00:22:46,499 --> 00:22:49,500
...the excavations are
disturbing the ground.
399
00:22:52,238 --> 00:22:54,638
LEAVY:
In Soho Square now,
we have some amber triggers
400
00:22:54,640 --> 00:22:55,840
on the leveling points.
401
00:22:55,842 --> 00:22:57,308
It's not to do
with the TBM;
402
00:22:57,310 --> 00:22:59,076
it's the new ticket hall.
403
00:22:59,078 --> 00:23:02,813
They're actually excavating
fairly deep in that area.
404
00:23:04,150 --> 00:23:06,951
NARRATOR:
Sensors on the House
of St. Barnabas
405
00:23:06,953 --> 00:23:08,819
have triggered alerts.
406
00:23:08,821 --> 00:23:11,355
It looks like cracks
in the rare plasterwork
407
00:23:11,357 --> 00:23:13,791
are getting worse.
408
00:23:13,793 --> 00:23:15,292
The corner behind me
409
00:23:15,294 --> 00:23:18,062
has been gently moving
towards the square.
410
00:23:18,064 --> 00:23:21,098
And we are watching the cracks
411
00:23:21,100 --> 00:23:23,267
that are forming
in the plasterwork.
412
00:23:23,269 --> 00:23:26,804
Now, we don't want to be panicky
about this,
413
00:23:26,806 --> 00:23:30,274
but you have to keep an eye
on what's going on.
414
00:23:30,276 --> 00:23:31,742
The main thing is to try
to ensure that
415
00:23:31,744 --> 00:23:32,777
it all stays up there.
416
00:23:36,182 --> 00:23:40,317
NARRATOR:
Tunnels beneath Soho put these
historic buildings at risk,
417
00:23:40,319 --> 00:23:43,254
but the stakes are even higher
to the east,
418
00:23:43,256 --> 00:23:46,590
where another team is digging
below the River Thames
419
00:23:46,592 --> 00:23:48,426
at Custom House.
420
00:23:52,165 --> 00:23:54,665
The train tunnels for Crossrail
421
00:23:54,667 --> 00:23:57,668
need to pass
under the Royal Docks here.
422
00:24:00,873 --> 00:24:04,608
In their Victorian heyday,
423
00:24:04,610 --> 00:24:06,744
these were some of the largest
docks in the world.
424
00:24:07,947 --> 00:24:10,047
And today,
they include London's
425
00:24:10,049 --> 00:24:15,686
largest exhibition space:
The Excel Center.
426
00:24:15,688 --> 00:24:17,288
The new Crossrail station
427
00:24:17,290 --> 00:24:19,089
will make it easier and faster
to get here,
428
00:24:19,091 --> 00:24:22,426
as well as
to London City Airport.
429
00:24:22,428 --> 00:24:25,162
Much of the old
Victorian infrastructure
430
00:24:25,164 --> 00:24:29,366
remains in place today,
including the Connaught Tunnel
431
00:24:29,368 --> 00:24:32,536
that runs
underneath the water here.
432
00:24:32,538 --> 00:24:33,904
Linda Miller,
433
00:24:33,906 --> 00:24:36,440
an American engineer,
heads a team that is attempting
434
00:24:36,442 --> 00:24:38,609
to rebuild this old tunnel
435
00:24:38,611 --> 00:24:41,712
to make it suitable
for modern high-speed trains.
436
00:24:41,714 --> 00:24:43,647
The mission
for the Connaught Tunnel team
437
00:24:43,649 --> 00:24:45,816
is to turn a 135-year-old
438
00:24:45,818 --> 00:24:48,319
beautiful piece
of Victorian architecture
439
00:24:48,321 --> 00:24:50,654
to a state-of-the-art
modern tunnel.
440
00:24:53,025 --> 00:24:55,226
NARRATOR:
The existing tunnel is too small
441
00:24:55,228 --> 00:24:56,861
for Crossrail's trains
to squeeze through.
442
00:24:59,098 --> 00:25:00,998
MILLER:
Well, I've been
on some very exciting jobs.
443
00:25:01,000 --> 00:25:04,235
I've been lucky enough to build
a new space launch complex
444
00:25:04,237 --> 00:25:06,237
at Cape Canaveral, Florida,
445
00:25:06,239 --> 00:25:08,272
and do tunnels
in other beautiful cities,
446
00:25:08,274 --> 00:25:09,974
but I reckon this is
my favorite job yet.
447
00:25:12,612 --> 00:25:14,745
I love the idea
that we're bringing
448
00:25:14,747 --> 00:25:19,517
beautiful old heritage railroad
back to life.
449
00:25:21,554 --> 00:25:25,623
NARRATOR:
The Connaught Tunnel was built
in 1878.
450
00:25:25,625 --> 00:25:28,559
Steam trains
once ran through here,
451
00:25:28,561 --> 00:25:31,362
shuttling passengers
back and forth
452
00:25:31,364 --> 00:25:32,997
to a ferry terminal.
453
00:25:35,434 --> 00:25:37,801
MILLER:
You may just see
the old coke deposits
454
00:25:37,803 --> 00:25:40,404
and memories of the steam trains
left above there,
455
00:25:40,406 --> 00:25:41,672
but actually, what I see
456
00:25:41,674 --> 00:25:44,074
is a tunnel that's
in cracking good condition,
457
00:25:44,076 --> 00:25:47,077
fantastically well built,
you know, really built to last.
458
00:25:53,786 --> 00:25:57,321
NARRATOR:
Dismantling and rebuilding
this robust underwater tunnel
459
00:25:57,323 --> 00:26:01,292
will require a complete
rethinking of the structure.
460
00:26:04,263 --> 00:26:06,697
For half of its length,
the Connaught tunnel
461
00:26:06,699 --> 00:26:09,500
is a single tunnel
with two sets of tracks.
462
00:26:11,203 --> 00:26:14,238
But not in the center
under the docks,
463
00:26:14,240 --> 00:26:16,373
where it splits into two.
464
00:26:16,375 --> 00:26:20,311
Linda's team must completely
rebuild this section,
465
00:26:20,313 --> 00:26:24,715
creating a single taller,
deeper, and wider tunnel
466
00:26:24,717 --> 00:26:27,718
big enough for two
Crossrail trains.
467
00:26:30,256 --> 00:26:31,622
MILLER:
The first job then
468
00:26:31,624 --> 00:26:33,657
is to start to deepen
this tunnel,
469
00:26:33,659 --> 00:26:36,460
and you can see
that's just what we've done,
470
00:26:36,462 --> 00:26:37,962
cutting away
and uncovering bricks
471
00:26:37,964 --> 00:26:42,166
that haven't seen the light
in 130 years.
472
00:26:44,203 --> 00:26:47,538
NARRATOR:
Linda's team must also remove
the steel rings
473
00:26:47,540 --> 00:26:50,541
that Victorian engineers used
to form arches,
474
00:26:50,543 --> 00:26:53,844
reinforcing
the tunnel roof here.
475
00:26:53,846 --> 00:26:55,079
But a survey has revealed
476
00:26:55,081 --> 00:26:57,348
that there is a problem
with this plan.
477
00:26:57,350 --> 00:26:58,949
MILLER:
It was always assumed
478
00:26:58,951 --> 00:27:01,619
that we could cut
these cast steel rings out
479
00:27:01,621 --> 00:27:04,421
and replace them with rings
that were slightly larger
480
00:27:04,423 --> 00:27:06,156
and that
that would all be fine
481
00:27:06,158 --> 00:27:08,959
because we had a really good
level of cover
482
00:27:08,961 --> 00:27:12,396
above the crown
of this old tunnel.
483
00:27:12,398 --> 00:27:16,300
So it was shock and dismay
after we had our first divers
484
00:27:16,302 --> 00:27:18,068
clear away quite a lot of silt
485
00:27:18,070 --> 00:27:19,837
that was at the bottom
of the docks
486
00:27:19,839 --> 00:27:21,472
and do a proper survey
487
00:27:21,474 --> 00:27:25,242
and find that actually,
we have no cover at all.
488
00:27:25,244 --> 00:27:28,379
NARRATOR:
That means that
the bottom of the dock
489
00:27:28,381 --> 00:27:30,514
is perilously close
to the steel rings.
490
00:27:30,516 --> 00:27:32,182
The current plan
to enlarge the tunnel
491
00:27:32,184 --> 00:27:34,918
could lead to deadly
consequences.
492
00:27:36,555 --> 00:27:38,522
MILLER:
The word we were
worried about is,
493
00:27:38,524 --> 00:27:40,958
"Oh, my gosh, as we try
and cut these rings off
494
00:27:40,960 --> 00:27:44,728
"of the crown of this roof
and that much water is above us,
495
00:27:44,730 --> 00:27:46,630
catastrophic inundation,"
496
00:27:46,632 --> 00:27:48,499
or the sluicing in,
uncontrolled sluicing in
497
00:27:48,501 --> 00:27:50,868
of the Royal Docks
into this tunnel
498
00:27:50,870 --> 00:27:54,738
became quite the real...
well, terror, really.
499
00:27:56,676 --> 00:27:58,776
NARRATOR:
With little or no soil
500
00:27:58,778 --> 00:28:01,145
separating the tunnel
from the water above,
501
00:28:01,147 --> 00:28:05,482
removing the steel rings could
cause a catastrophic breach.
502
00:28:08,354 --> 00:28:11,088
The only way
to expand the tunnel safely
503
00:28:11,090 --> 00:28:15,426
is to seal off the passage
with giant steel barriers,
504
00:28:15,428 --> 00:28:17,127
drain the water,
505
00:28:17,129 --> 00:28:19,496
and rebuild the tunnel
top down
506
00:28:19,498 --> 00:28:21,365
from inside this dry workspace.
507
00:28:24,704 --> 00:28:28,839
But closing off the waterway
here could be a problem.
508
00:28:28,841 --> 00:28:32,543
It's the only way river traffic
can pass to and from
509
00:28:32,545 --> 00:28:36,113
the city's largest
exhibition space, Excel,
510
00:28:36,115 --> 00:28:38,182
home to the annual
London Boat Show.
511
00:28:38,184 --> 00:28:43,020
They can't start the process
until after the Boat Show,
512
00:28:43,022 --> 00:28:46,590
when the road bridge can be
opened to allow the ships out.
513
00:28:46,592 --> 00:28:49,860
And then they have
a narrow time window
514
00:28:49,862 --> 00:28:52,529
of just six months
to complete the work.
515
00:28:52,531 --> 00:28:54,665
If the passage
isn't open by then,
516
00:28:54,667 --> 00:28:58,302
naval ships arriving
for the annual Defense Show
517
00:28:58,304 --> 00:29:02,106
won't be able to reach the hall.
518
00:29:02,108 --> 00:29:06,176
Time is also against
another team...
519
00:29:08,614 --> 00:29:11,949
...three miles west
along the River Thames
520
00:29:11,951 --> 00:29:16,520
in the busy new financial
district of Canary Wharf,
521
00:29:16,522 --> 00:29:19,556
where Crossrail's
ambitious timber roof
522
00:29:19,558 --> 00:29:21,158
is slowly taking shape.
523
00:29:23,696 --> 00:29:25,863
But deep below the roof,
524
00:29:25,865 --> 00:29:28,098
engineers are preparing
for a key milestone.
525
00:29:29,735 --> 00:29:31,835
One of the eight
tunnel boring machines
526
00:29:31,837 --> 00:29:33,704
is now nearing its first target.
527
00:29:36,175 --> 00:29:37,508
It must break through
528
00:29:37,510 --> 00:29:41,345
into Crossrail's vast new
Canary Wharf Station,
529
00:29:41,347 --> 00:29:43,280
connecting the tunnel
with the platform space.
530
00:29:45,951 --> 00:29:48,185
We're at the minus six level
of the Canary Wharf box,
531
00:29:48,187 --> 00:29:51,088
and we're just waiting
on our first TBM
532
00:29:51,090 --> 00:29:53,357
to pop its head through
for our first breakthrough.
533
00:29:56,695 --> 00:30:00,063
This is our first breakthrough
on an existing structure,
534
00:30:00,065 --> 00:30:04,067
so for us,
this is all about making sure
535
00:30:04,069 --> 00:30:05,469
that the machine is
where it should be.
536
00:30:07,907 --> 00:30:12,209
NARRATOR:
Canary Wharf Station is
a giant six-level box
537
00:30:12,211 --> 00:30:14,378
with a garden, shops,
538
00:30:14,380 --> 00:30:16,780
and restaurants
on the upper floors,
539
00:30:16,782 --> 00:30:19,283
and the platforms
deep below ground.
540
00:30:19,285 --> 00:30:22,886
The team here must drive
its tunnel boring machine
541
00:30:22,888 --> 00:30:25,322
through the station's
concrete walls,
542
00:30:25,324 --> 00:30:27,925
hitting a specially
designed target.
543
00:30:36,836 --> 00:30:41,772
Crossrail's first breakthrough
is just a few inches away.
544
00:30:55,120 --> 00:30:56,720
(applause)
545
00:31:04,029 --> 00:31:05,696
(cheering)
546
00:31:12,905 --> 00:31:14,938
NARRATOR:
Everyone is jubilant
547
00:31:14,940 --> 00:31:18,408
as the machine hits its target
spot on.
548
00:31:18,410 --> 00:31:22,179
Canary Wharf Station is now
connected to the new tunnel...
549
00:31:22,181 --> 00:31:24,147
MAN:
One, two, three!
550
00:31:24,149 --> 00:31:25,949
(cheering)
551
00:31:25,951 --> 00:31:29,219
NARRATOR:
...putting the project
one step closer
552
00:31:29,221 --> 00:31:31,922
to joining up with the hub
at Tottenham Court Road.
553
00:31:38,230 --> 00:31:43,767
But in neighboring Soho Square,
the robot laser trackers
554
00:31:43,769 --> 00:31:46,904
have detected a dangerous shift
in the ground,
555
00:31:46,906 --> 00:31:50,908
threatening
the House of St. Barnabas
556
00:31:50,910 --> 00:31:53,377
and putting its rare
Rococo decor in peril.
557
00:31:55,147 --> 00:31:59,349
Engineers must stop the earth
from sinking
558
00:31:59,351 --> 00:32:01,051
before it gets any worse.
559
00:32:03,389 --> 00:32:05,422
Before tunneling began,
560
00:32:05,424 --> 00:32:08,759
they dug 22 shafts
around Central London,
561
00:32:08,761 --> 00:32:12,296
part of a subterranean system
to protect historic buildings.
562
00:32:16,468 --> 00:32:20,370
Four of these shafts are
in Soho Square.
563
00:32:20,372 --> 00:32:25,075
A spider's web of thin tubes
stretches out from each shaft.
564
00:32:25,077 --> 00:32:28,211
Each tube has holes
every three feet.
565
00:32:28,213 --> 00:32:32,182
Engineers send a narrow device
called a packer
566
00:32:32,184 --> 00:32:35,585
to the spot
where the ground is settling.
567
00:32:35,587 --> 00:32:40,157
The packer precision-injects
grout to fill up any voids,
568
00:32:40,159 --> 00:32:43,360
lifting the earth back
to its original position,
569
00:32:43,362 --> 00:32:46,930
protecting plasterwork,
preventing further cracks,
570
00:32:46,932 --> 00:32:48,598
and keeping buildings safe.
571
00:32:51,870 --> 00:32:54,905
MAN:
TAM number 46 then, yeah?
572
00:32:54,907 --> 00:32:59,443
NARRATOR:
This shaft in the southeast
corner of Soho Square
573
00:32:59,445 --> 00:33:04,281
is where grouters Lloyd and Tony
work to shore up the buildings.
574
00:33:04,283 --> 00:33:06,183
LLOYD:
This is what we call a packer.
575
00:33:06,185 --> 00:33:07,517
This rubber part here
will inflate.
576
00:33:07,519 --> 00:33:10,821
That will form a seal to prevent
any grout coming back out.
577
00:33:10,823 --> 00:33:13,523
90 meters is a long way
to push the packer,
578
00:33:13,525 --> 00:33:16,059
but you take the rough
with the smooth, I think.
579
00:33:16,061 --> 00:33:17,327
2-6-1-5!
580
00:33:17,329 --> 00:33:20,497
Okay, 2-6-1-5.
581
00:33:25,804 --> 00:33:28,238
NARRATOR:
Lloyd and Tony spend
up to 12 hours a day
582
00:33:28,240 --> 00:33:31,975
down this shaft,
packing holes under Soho Square.
583
00:33:33,746 --> 00:33:35,846
LLOYD:
Okay, that's depth.
584
00:33:35,848 --> 00:33:37,781
inflate the packer.
585
00:33:44,690 --> 00:33:47,124
That's ready to start pumping!
586
00:33:47,126 --> 00:33:48,892
Yeah, pumping now.
587
00:33:52,064 --> 00:33:54,664
I've been on the job for
about 16 months.
588
00:33:54,666 --> 00:33:58,301
Tony's been with us for
about six months.
589
00:33:58,303 --> 00:33:59,936
We generally tend
to stick together
590
00:33:59,938 --> 00:34:01,605
as a team as well,
you know?
591
00:34:01,607 --> 00:34:03,140
Yeah, we do come...
592
00:34:03,142 --> 00:34:04,741
I mean, not too close,
obviously.
593
00:34:04,743 --> 00:34:07,978
You don't want to get too close
in a place like this.
594
00:34:07,980 --> 00:34:09,346
You get used to talking
to yourself,
595
00:34:09,348 --> 00:34:10,747
but apart from that,
it's all right.
596
00:34:10,749 --> 00:34:13,583
13-3-0-7-5!
597
00:34:13,585 --> 00:34:15,285
Okay, up on the reel!
598
00:34:22,161 --> 00:34:23,093
Whoa!
599
00:34:30,302 --> 00:34:35,272
Welcome to the House of
St. Barnabas periodic meeting.
600
00:34:35,274 --> 00:34:38,508
NARRATOR:
In order to keep
these historic buildings safe,
601
00:34:38,510 --> 00:34:41,578
the Crossrail team
meets once a month
602
00:34:41,580 --> 00:34:44,948
to analyze
the laser leveling data.
603
00:34:44,950 --> 00:34:47,017
WOMAN:
And then the summary sheet
604
00:34:47,019 --> 00:34:51,354
won't have any triggers
unless we get real movements.
605
00:34:51,356 --> 00:34:54,925
NARRATOR:
They'll keep a close eye
on the House of St. Barnabas
606
00:34:54,927 --> 00:34:57,527
and its Rococo plasterwork.
607
00:34:57,529 --> 00:34:59,830
SCOTT:
The charming lady here
has survived
608
00:34:59,832 --> 00:35:04,367
to keep us entertained
in the 21st century
609
00:35:04,369 --> 00:35:06,002
and I hope for many more.
610
00:35:07,806 --> 00:35:10,607
NARRATOR:
Finding a way to protect
historic buildings above ground
611
00:35:10,609 --> 00:35:13,777
has been tough,
but a few miles away,
612
00:35:13,779 --> 00:35:16,546
engineer Linda Miller struggles
613
00:35:16,548 --> 00:35:18,782
with a potentially
disastrous situation.
614
00:35:18,784 --> 00:35:23,186
She needs to expand
a 19th-century tunnel
615
00:35:23,188 --> 00:35:26,223
running beneath the docks
next to the River Thames.
616
00:35:26,225 --> 00:35:30,460
But the lack of headroom
has created a huge problem.
617
00:35:30,462 --> 00:35:33,597
Now she's racing to find a way
to do the job
618
00:35:33,599 --> 00:35:35,866
without causing a flood.
619
00:35:43,408 --> 00:35:44,741
Faced with the reality
620
00:35:44,743 --> 00:35:48,378
that she will first need
to drain the channel...
621
00:35:48,380 --> 00:35:49,679
MILLER:
Thank you very much.
622
00:35:49,681 --> 00:35:51,181
How exciting!
623
00:35:51,183 --> 00:35:54,484
NARRATOR:
...Linda decides to read up
on the tunnel's history.
624
00:35:54,486 --> 00:35:57,120
Now, this was the later stamp...
625
00:35:57,122 --> 00:36:01,458
The original drawings,
135-year-old drawings there.
626
00:36:01,460 --> 00:36:03,793
DAVID WILDE:
We've been presented
with the same problems
627
00:36:03,795 --> 00:36:05,562
as the original construction,
basically.
628
00:36:05,564 --> 00:36:07,864
A lot of it's to do with water
629
00:36:07,866 --> 00:36:10,033
and how you actually build
something
630
00:36:10,035 --> 00:36:12,536
with all the water around it.
631
00:36:14,840 --> 00:36:19,075
NARRATOR:
She discovers that her plan
actually mirrors the techniques
632
00:36:19,077 --> 00:36:22,379
used by the engineers
who originally built it.
633
00:36:23,982 --> 00:36:25,949
MILLER:
"Existing dam."
634
00:36:25,951 --> 00:36:28,084
See, that's history
repeating itself there.
635
00:36:28,086 --> 00:36:29,920
Instead of tunneling
underneath the ground,
636
00:36:29,922 --> 00:36:33,023
they've actually excavated
around the profile
637
00:36:33,025 --> 00:36:36,660
and then installed the tunnel
in there.
638
00:36:36,662 --> 00:36:40,030
So they've built it from
the top downwards, effectively.
639
00:36:40,032 --> 00:36:43,200
MILLER:
Looking at the two twin-walled
cofferdams standing there
640
00:36:43,202 --> 00:36:47,437
with "1872," "1874" written
in the corner of the drawings,
641
00:36:47,439 --> 00:36:50,373
I think it was meant to be.
642
00:36:52,911 --> 00:36:55,378
NARRATOR:
Finally, the London Boat Show
is over.
643
00:36:58,350 --> 00:37:01,751
As the last luxury yachts
cruise out of the docks,
644
00:37:01,753 --> 00:37:06,223
a narrow window of opportunity
opens for Linda's team.
645
00:37:06,225 --> 00:37:09,526
They can now close the passage
directly above the tunnel
646
00:37:09,528 --> 00:37:10,760
and drain it.
647
00:37:10,762 --> 00:37:14,197
But they still don't have
the luxury of time.
648
00:37:14,199 --> 00:37:16,766
They will have
to reopen it again
649
00:37:16,768 --> 00:37:20,036
in time for navy ships
to get to the Defense Show
650
00:37:20,038 --> 00:37:22,272
in just six months.
651
00:37:22,274 --> 00:37:23,940
MILLER:
We'll try and quickly
get in here,
652
00:37:23,942 --> 00:37:25,175
do open heart surgery
653
00:37:25,177 --> 00:37:28,044
on this tunnel from the top,
rebuild it into a larger tunnel,
654
00:37:28,046 --> 00:37:31,848
and get out of here by the time
the Defense Show comes.
655
00:37:31,850 --> 00:37:34,684
It's hard work.
656
00:37:34,686 --> 00:37:38,121
NARRATOR:
The last of the water is drained
from the dock,
657
00:37:38,123 --> 00:37:43,727
exposing the 137-year-old roof
of the Connaught Tunnel.
658
00:37:46,898 --> 00:37:48,565
PAUL OSBORNE:
We've got lots of workfronts
going on,
659
00:37:48,567 --> 00:37:51,635
so we're working in the tunnel,
working in the dock,
660
00:37:51,637 --> 00:37:53,403
we're all a team, basically,
661
00:37:53,405 --> 00:37:55,071
working together
trying to achieve one goal.
662
00:37:55,073 --> 00:37:59,209
NARRATOR:
The team must complete
a laundry list of challenges
663
00:37:59,211 --> 00:38:01,177
in a very short time.
664
00:38:01,179 --> 00:38:03,546
First task:
665
00:38:03,548 --> 00:38:06,783
remove the steel rings
lining the twin tunnel section.
666
00:38:07,886 --> 00:38:09,886
What you're able to see
quite clearly here,
667
00:38:09,888 --> 00:38:11,588
now that the docks are empty,
668
00:38:11,590 --> 00:38:14,157
you can see
the cast steel barrel.
669
00:38:14,159 --> 00:38:18,595
The Crossrail tunnel is going
to be wider and rectangular
670
00:38:18,597 --> 00:38:22,365
and fit its haunches
within the old tunnel.
671
00:38:25,170 --> 00:38:27,871
NARRATOR:
Carefully, the team
removes the rings
672
00:38:27,873 --> 00:38:32,275
without triggering a collapse.
673
00:38:32,277 --> 00:38:35,045
But as they cut the steel away
in this corner,
674
00:38:35,047 --> 00:38:38,982
they reveal a completely
unexpected brick arch behind.
675
00:38:40,619 --> 00:38:42,018
That's a problem.
676
00:38:42,020 --> 00:38:45,789
NARRATOR:
The new tunnel is supposed
to fit inside this arch,
677
00:38:45,791 --> 00:38:50,193
but there's not enough clearance
for the new tunnel to fit in.
678
00:38:50,195 --> 00:38:52,095
That's got to be removed.
679
00:38:56,201 --> 00:38:58,335
NARRATOR:
They can't just remove
the brick arch
680
00:38:58,337 --> 00:39:00,236
behind the steel rings
681
00:39:00,238 --> 00:39:03,139
because it could be supporting
the docks above.
682
00:39:04,676 --> 00:39:06,443
MILLER:
You're not going to be able
to take a section out of this
683
00:39:06,445 --> 00:39:10,180
and still be able to hold on
to your arching effect.
684
00:39:10,182 --> 00:39:11,381
Pretty unlikely.
685
00:39:11,383 --> 00:39:12,349
Unlikely.
686
00:39:12,351 --> 00:39:14,217
Is it the same
on the other side?
687
00:39:14,219 --> 00:39:15,819
Yeah, but we don't know
how far.
688
00:39:15,821 --> 00:39:17,721
All the rings they've
taken out so far,
689
00:39:17,723 --> 00:39:19,723
we've got the reduced dimension.
690
00:39:19,725 --> 00:39:21,191
All right.
691
00:39:21,193 --> 00:39:23,526
Yeah, this is yet another time
692
00:39:23,528 --> 00:39:26,329
when this tunnel
shows us new mysteries.
693
00:39:26,331 --> 00:39:29,599
This job actually started
construction a year ahead
694
00:39:29,601 --> 00:39:32,369
of when everyone said
that it needed to,
695
00:39:32,371 --> 00:39:35,939
and it was because
a predecessor of mine said,
696
00:39:35,941 --> 00:39:37,941
"It's going to be
a bucket of spiders."
697
00:39:37,943 --> 00:39:41,511
And oh, my goodness,
have we used every bit of that,
698
00:39:41,513 --> 00:39:43,546
and now we're staring
at the end date
699
00:39:43,548 --> 00:39:46,750
that we never thought that we
would need to be worried about.
700
00:39:48,620 --> 00:39:51,888
NARRATOR:
Linda and the team are already
facing a very tight deadline.
701
00:39:51,890 --> 00:39:54,724
They can't afford
this new delay.
702
00:39:54,726 --> 00:39:58,361
And they quickly discover
that the brickwork
703
00:39:58,363 --> 00:40:00,497
is unusually tough.
704
00:40:00,499 --> 00:40:02,499
MILLER:
The mortar between them
705
00:40:02,501 --> 00:40:04,701
is 100% full.
706
00:40:04,703 --> 00:40:06,302
There's no gaps here at all.
707
00:40:06,304 --> 00:40:09,272
It's a fantastic,
fantastic job.
708
00:40:09,274 --> 00:40:13,643
And then the 135 years of earth
pressure and water against it
709
00:40:13,645 --> 00:40:16,513
has sealed it up
to where it's behaving
710
00:40:16,515 --> 00:40:20,283
more like stainless steel
than it is brick and mortar.
711
00:40:20,285 --> 00:40:25,488
NARRATOR:
The strong mortar is now causing
the latest problem for the team.
712
00:40:25,490 --> 00:40:29,025
They can't get the bricks out
quickly enough.
713
00:40:29,027 --> 00:40:30,860
OSBOURNE:
Just over a third
of the way to go.
714
00:40:30,862 --> 00:40:34,063
It's quite slow going,
this brickwork.
715
00:40:34,065 --> 00:40:36,299
You know I've seen brickwork
like this taken down,
716
00:40:36,301 --> 00:40:37,600
and all you normally need to do
717
00:40:37,602 --> 00:40:39,002
is have a couple of stabs
at the mortar
718
00:40:39,004 --> 00:40:41,237
and a whole brick layer
goes off;
719
00:40:41,239 --> 00:40:44,073
couple more stabs at the mortar,
the next layer goes off.
720
00:40:44,075 --> 00:40:47,510
I know the men are taking
a short break here now,
721
00:40:47,512 --> 00:40:50,680
but hand-breaking out
this 130-year-old brick
722
00:40:50,682 --> 00:40:52,782
is just, well, hard work.
723
00:40:52,784 --> 00:40:53,783
It's going to take a while.
724
00:40:53,785 --> 00:40:54,818
I know they're working it
night and day,
725
00:40:54,820 --> 00:40:56,085
I know they've got
extra crews in,
726
00:40:56,087 --> 00:40:57,020
but there's not much time.
727
00:41:00,926 --> 00:41:03,793
Here we are in the last throes
of the last couple of weeks
728
00:41:03,795 --> 00:41:05,361
before we put the water back in.
729
00:41:05,363 --> 00:41:07,897
We couldn't be throwing
more into it than this.
730
00:41:20,345 --> 00:41:23,379
NARRATOR:
Linda's team works
around the clock
731
00:41:23,381 --> 00:41:26,883
to remove the protruding arch
inside the Connaught Tunnel
732
00:41:26,885 --> 00:41:29,219
and build a new roof
of steel and concrete
733
00:41:29,221 --> 00:41:31,688
before they must re-flood
the channel
734
00:41:31,690 --> 00:41:34,657
in the next 24 hours.
735
00:41:37,462 --> 00:41:40,864
The final push pays off
736
00:41:40,866 --> 00:41:45,401
as water streams back
into the area.
737
00:41:45,403 --> 00:41:47,704
Linda and the team
have completed the tunnel
738
00:41:47,706 --> 00:41:51,307
just in the nick of time.
739
00:41:51,309 --> 00:41:53,810
WOMAN:
I can't believe you can see
all the way through!
740
00:41:59,217 --> 00:42:01,317
No one's ever gonna have
been able to see that
741
00:42:01,319 --> 00:42:02,785
all the way through.
742
00:42:02,787 --> 00:42:04,087
MILLER:
Doesn't it look fantastic?
743
00:42:04,089 --> 00:42:06,089
I know, it's mad!
744
00:42:08,860 --> 00:42:12,662
I can't believe
it's finally done.
745
00:42:12,664 --> 00:42:13,997
Feels so good.
746
00:42:13,999 --> 00:42:18,134
Like, we're directly
below the docks right now
747
00:42:18,136 --> 00:42:19,636
and you wouldn't know.
748
00:42:19,638 --> 00:42:24,207
I know, below meters
of water there above us.
749
00:42:24,209 --> 00:42:27,477
My gosh, we were working
like dogs, weren't we, 24/7?
750
00:42:27,479 --> 00:42:29,946
It couldn't have been closer,
it couldn't have been closer.
751
00:42:29,948 --> 00:42:30,880
WOMAN:
We've done it.
752
00:42:35,820 --> 00:42:39,956
NARRATOR:
With the tunnel complete,
the dock can reopen,
753
00:42:39,958 --> 00:42:43,693
allowing the military ships
to pass through.
754
00:42:45,063 --> 00:42:48,164
The Excel's Defense Show
can go ahead on schedule.
755
00:42:53,905 --> 00:42:58,942
This is the new Connaught Tunnel
for the next 120 years.
756
00:42:58,944 --> 00:43:01,010
So you need to get
out of the way here
757
00:43:01,012 --> 00:43:02,946
because trains are gonna start
coming through.
758
00:43:06,184 --> 00:43:09,719
NARRATOR:
While this old tunnel has been
given a new lease of life,
759
00:43:09,721 --> 00:43:13,156
at Tottenham Court Road,
a brand new tunnel
760
00:43:13,158 --> 00:43:15,592
will soon squeeze through
the congested earth here.
761
00:43:22,801 --> 00:43:26,703
The thousand-ton
tunnel-building monster
762
00:43:26,705 --> 00:43:30,006
is finally entering
the Eye of the Needle.
763
00:43:36,548 --> 00:43:39,282
Welcome, everyone,
to Sunday morning the 8th.
764
00:43:39,284 --> 00:43:42,585
NARRATOR:
This is the day Steve's team
has been working towards.
765
00:43:42,587 --> 00:43:44,420
That's where we are
at the moment,
766
00:43:44,422 --> 00:43:47,256
just touching the side
of Charing Cross Road.
767
00:43:47,258 --> 00:43:48,958
PARKER:
We're under the site
of the old Astoria Theatre,
768
00:43:48,960 --> 00:43:49,993
aren't we, Willie?
769
00:43:49,995 --> 00:43:51,260
ARCHIBALD:
Yep.
770
00:43:52,631 --> 00:43:54,797
NARRATOR:
Today, the tunnel-boring machine
771
00:43:54,799 --> 00:43:58,534
will reach the narrowest point
of its route across London.
772
00:43:58,536 --> 00:43:59,869
MAN:
So the crossing starts
773
00:43:59,871 --> 00:44:01,671
on back shift this afternoon,
774
00:44:01,673 --> 00:44:03,740
and I think we're going
to be there, yeah.
775
00:44:03,742 --> 00:44:05,341
Today is the critical day.
776
00:44:05,343 --> 00:44:07,777
It's the start of passing
over the Northern Line,
777
00:44:07,779 --> 00:44:09,779
and so this is
the critical point,
778
00:44:09,781 --> 00:44:12,882
the culmination of a lot of work
over the last couple of months.
779
00:44:14,986 --> 00:44:18,221
So people getting off the train
in the next hour or so
780
00:44:18,223 --> 00:44:20,857
will not realize that
above their head
781
00:44:20,859 --> 00:44:23,793
is a 900-ton,
7.1 meter-diameter
782
00:44:23,795 --> 00:44:25,862
tunneling machine.
783
00:44:25,864 --> 00:44:30,800
NARRATOR:
It's vital the close encounter
doesn't cause water or concrete
784
00:44:30,802 --> 00:44:36,339
to fall onto the Tube platform
below, which could spark panic.
785
00:44:36,341 --> 00:44:37,740
General comment is to say,
786
00:44:37,742 --> 00:44:39,509
"Be aware of proximity
of LU assets."
787
00:44:39,511 --> 00:44:41,544
MAN:
I mean, I would like Ed
to keep an eye on the belt.
788
00:44:41,546 --> 00:44:42,545
Yeah, just extra vigilance.
789
00:44:49,754 --> 00:44:51,888
So over the next 20 rings,
790
00:44:51,890 --> 00:44:55,324
we're directly above
the Northern Line platform.
791
00:44:55,326 --> 00:44:56,826
The Eye of the Needle.
792
00:44:56,828 --> 00:44:59,462
We're just about to go
through it.
793
00:44:59,464 --> 00:45:00,563
(phone ringing)
794
00:45:00,565 --> 00:45:02,265
Hello?
795
00:45:02,267 --> 00:45:03,066
Hello, Ed.
796
00:45:03,068 --> 00:45:04,067
Hi, Steve, how you doing?
797
00:45:04,069 --> 00:45:06,069
We've got one more ring to go
798
00:45:06,071 --> 00:45:08,938
before the cutter head
gets in line with the angle
799
00:45:08,940 --> 00:45:10,273
of the Northbound Line.
800
00:45:10,275 --> 00:45:13,776
Tim Morrison of LU said
he was down this morning,
801
00:45:13,778 --> 00:45:15,478
he was there, and he said
802
00:45:15,480 --> 00:45:17,914
he could hear the TBM
and hear the miners.
803
00:45:17,916 --> 00:45:20,683
(faint drilling noises)
804
00:45:22,320 --> 00:45:23,619
BATTY:
We're that close,
805
00:45:23,621 --> 00:45:25,088
so you can actually hear
what we're doing here.
806
00:45:25,090 --> 00:45:26,155
PARKER:
Yes, he could hear,
807
00:45:26,157 --> 00:45:27,590
but that with no trains running.
808
00:45:27,592 --> 00:45:31,327
Our one concern is that there
are cracks within London clay,
809
00:45:31,329 --> 00:45:33,162
some of the water could ease out
810
00:45:33,164 --> 00:45:35,998
and find the simplest path
of travel,
811
00:45:36,000 --> 00:45:38,801
which could be
the big platform tunnel.
812
00:45:56,154 --> 00:45:57,487
BATTY:
The TBM cutter head
813
00:45:57,489 --> 00:45:59,622
is now directly above
814
00:45:59,624 --> 00:46:02,859
the Northern Line
northbound station platform,
815
00:46:02,861 --> 00:46:06,963
so about 850 millimeters
below my feet
816
00:46:06,965 --> 00:46:10,633
is the crown of their tunnel,
so not a big distance at all.
817
00:46:10,635 --> 00:46:12,568
You see where there's
a blockwork wall here,
818
00:46:12,570 --> 00:46:14,771
just behind the tiled edge?
819
00:46:14,773 --> 00:46:16,639
That is pretty much
the center line
820
00:46:16,641 --> 00:46:17,974
where the tunneling machine
821
00:46:17,976 --> 00:46:20,109
is actually
crossing this structure.
822
00:46:20,111 --> 00:46:23,513
NARRATOR:
With the tunneling machine
less than three feet above,
823
00:46:23,515 --> 00:46:26,482
the pressure on the Northern
Line platform tunnel
824
00:46:26,484 --> 00:46:29,385
will be immense.
825
00:46:29,387 --> 00:46:32,388
The team is worried
about lubricating fluid
826
00:46:32,390 --> 00:46:35,258
pumped into the earth
ahead of the machine
827
00:46:35,260 --> 00:46:39,328
being forced through the wall
into the platform.
828
00:46:39,330 --> 00:46:41,030
MORRISON:
Sam is one of the guys
829
00:46:41,032 --> 00:46:43,199
who's been based down
on the platform.
830
00:46:43,201 --> 00:46:45,034
He's specifically looking
for any fluid ingress
831
00:46:45,036 --> 00:46:46,702
from the tunneling machine,
because that is something
832
00:46:46,704 --> 00:46:48,404
that we are concerned
as a possibility.
833
00:46:48,406 --> 00:46:49,806
SAM:
The tunneling machine
at the moment
834
00:46:49,808 --> 00:46:52,542
is quite literally
above the tunnel crown.
835
00:46:52,544 --> 00:46:54,911
There is that apprehension
836
00:46:54,913 --> 00:46:58,214
because there is a small risk
that we could see some ingress,
837
00:46:58,216 --> 00:47:00,650
and so I guess that makes it
more exciting.
838
00:47:05,523 --> 00:47:06,956
NARRATOR:
With the tunneling machine
839
00:47:06,958 --> 00:47:08,624
now threading
through the Eye of the Needle,
840
00:47:08,626 --> 00:47:12,128
the team must continue their
vigil throughout the night.
841
00:47:28,980 --> 00:47:32,281
As London sleeps...
842
00:47:32,283 --> 00:47:35,084
(whirring)
843
00:47:35,086 --> 00:47:38,354
...the 490-foot-long
earth-eating giant
844
00:47:38,356 --> 00:47:40,823
continues its relentless drive.
845
00:47:43,761 --> 00:47:47,797
With every passing moment,
the cutter head of the machine
846
00:47:47,799 --> 00:47:50,466
draws ever closer
to the Northern Line
847
00:47:50,468 --> 00:47:52,068
and its escalators.
848
00:47:58,409 --> 00:47:59,675
Willie, got an update
where we are?
849
00:47:59,677 --> 00:48:03,346
Yep, they're building 3024
just now.
850
00:48:03,348 --> 00:48:06,549
NARRATOR:
Finally, the team and machine
851
00:48:06,551 --> 00:48:10,386
squeak through the tightest spot
with only inches to spare.
852
00:48:10,388 --> 00:48:12,188
Yep, okay!
853
00:48:12,190 --> 00:48:14,724
NARRATOR:
A complete success--
854
00:48:14,726 --> 00:48:19,128
no terrified passengers,
no evacuated platforms.
855
00:48:19,130 --> 00:48:21,397
It's time to breathe again.
856
00:48:21,399 --> 00:48:23,432
PARKER:
We've passed
over two platform tunnels
857
00:48:23,434 --> 00:48:26,469
with a 900-ton
tunneling machine.
858
00:48:26,471 --> 00:48:28,237
That's even a first,
I think.
859
00:48:28,239 --> 00:48:29,105
MORRISON:
Yes, it is, yeah.
860
00:48:29,107 --> 00:48:30,172
Cheers.
861
00:48:31,676 --> 00:48:33,876
BATTY:
The lads have been working
down here really hard,
862
00:48:33,878 --> 00:48:36,579
and so have the guys
up in the control room.
863
00:48:36,581 --> 00:48:37,880
A big relief.
864
00:48:37,882 --> 00:48:39,782
I'm chuffed that
we've done it so well
865
00:48:39,784 --> 00:48:41,083
and we've had such good results.
866
00:48:41,085 --> 00:48:44,353
We've done it, yeah,
got through the tricky spot.
867
00:48:44,355 --> 00:48:46,088
PARKER:
The trains have kept running.
868
00:48:46,090 --> 00:48:49,325
Passengers haven't known that
we've been there.
869
00:48:50,662 --> 00:48:52,228
It's been a great achievement,
870
00:48:52,230 --> 00:48:54,196
and I'm glad to be part
of that team.
871
00:48:54,198 --> 00:48:56,899
NARRATOR:
The team leaves
a perfectly formed Tube tunnel
872
00:48:56,901 --> 00:49:00,436
in their wake,
873
00:49:00,438 --> 00:49:02,571
gradually closing the distance
874
00:49:02,573 --> 00:49:04,840
to the new financial heart
in East London.
875
00:49:12,817 --> 00:49:16,118
Here at Crossrail's
Canary Wharf Station,
876
00:49:16,120 --> 00:49:21,290
Phil's team is locking
the last beams into place.
877
00:49:28,466 --> 00:49:30,299
DUFFY:
Everything's going perfect,
thank God.
878
00:49:30,301 --> 00:49:32,435
Everything is good.
879
00:49:32,437 --> 00:49:34,637
It's the biggest project
that we've done.
880
00:49:34,639 --> 00:49:36,605
Something to be proud of,
I suppose.
881
00:49:36,607 --> 00:49:40,142
NARRATOR:
Final piece of the puzzle:
882
00:49:40,144 --> 00:49:44,280
780 inflatable panels
known as cushions
883
00:49:44,282 --> 00:49:45,681
that will fill the gaps
884
00:49:45,683 --> 00:49:47,984
and cover most
of the rooftop garden.
885
00:49:51,289 --> 00:49:55,324
Installing them requires
a head for heights,
886
00:49:55,326 --> 00:49:57,927
so they've assembled
a crew of builders
887
00:49:57,929 --> 00:49:59,328
with a special talent.
888
00:49:59,330 --> 00:50:00,796
MAN:
They're rock climbers
and mountain climbers,
889
00:50:00,798 --> 00:50:05,301
so they're used to heights,
and yes, a very skilled trade.
890
00:50:08,406 --> 00:50:11,674
Basically, they're just
unwrapping the cushion now.
891
00:50:11,676 --> 00:50:14,210
It comes all folded up,
they unfold it.
892
00:50:14,212 --> 00:50:16,812
They have to put
aluminum sections
893
00:50:16,814 --> 00:50:18,514
which run down the edge.
894
00:50:18,516 --> 00:50:21,117
Then they'll connect it
into the system,
895
00:50:21,119 --> 00:50:23,152
connect the air pipes,
and blow it up.
896
00:50:23,154 --> 00:50:25,621
Sounds simple;
little bit more difficult.
897
00:50:25,623 --> 00:50:28,257
NARRATOR:
Fitting the first cushion
on the lower outside edge
898
00:50:28,259 --> 00:50:31,494
will be a real test.
899
00:50:34,232 --> 00:50:37,033
Below is a 65-foot drop.
900
00:50:37,035 --> 00:50:38,534
Because we're installing
the cushion
901
00:50:38,536 --> 00:50:39,635
almost on the vertical face,
902
00:50:39,637 --> 00:50:42,738
there is no area
for a safety net.
903
00:50:42,740 --> 00:50:44,040
This is the...
904
00:50:44,042 --> 00:50:46,642
The most susceptible point
of the installation
905
00:50:46,644 --> 00:50:48,744
is when it's opened.
906
00:50:48,746 --> 00:50:52,181
If the wind catches it, then
that's the worst-case scenario.
907
00:50:52,183 --> 00:50:55,418
Once it's got the rails on it
and it's attached, it's secure.
908
00:50:58,623 --> 00:51:00,289
They're now fitting
the air inlet,
909
00:51:00,291 --> 00:51:05,227
so any moment now, you'll see
the cushion inflating.
910
00:51:07,999 --> 00:51:11,300
It is actually starting
to inflate now.
911
00:51:13,771 --> 00:51:19,308
One done, about 750 to go.
912
00:51:22,180 --> 00:51:23,345
I'm a happy bunny.
913
00:51:29,687 --> 00:51:31,187
MAN:
It's growing, you know?
914
00:51:31,189 --> 00:51:34,223
It's getting more beautiful
every day.
915
00:51:37,428 --> 00:51:39,929
NARRATOR:
130 feet below the roof,
916
00:51:39,931 --> 00:51:44,700
the station's 790-foot-long
platforms are being fitted out.
917
00:51:47,038 --> 00:51:51,006
And the final timber
slots into place on the roof.
918
00:51:51,008 --> 00:51:54,310
All our timbers are fitted,
everything is done now.
919
00:51:54,312 --> 00:51:56,779
Someone else's problem now.
920
00:51:56,781 --> 00:51:59,448
I'm out of here,
back to Ireland.
921
00:51:59,450 --> 00:52:07,323
(humming cheerful tune)
922
00:52:10,828 --> 00:52:13,863
NARRATOR:
So far, Crossrail's
10,000 employees
923
00:52:13,865 --> 00:52:15,898
have put in a hundred million
working hours...
924
00:52:15,900 --> 00:52:18,100
(cheering)
925
00:52:18,102 --> 00:52:22,004
...poured over 88 million
cubic feet of concrete,
926
00:52:22,006 --> 00:52:25,975
and laid over 200,000
tunnel segments.
927
00:52:29,981 --> 00:52:34,984
In 2018, the ticket halls
will open
928
00:52:34,986 --> 00:52:37,419
and the escalators
start running.
929
00:52:37,421 --> 00:52:41,924
Before then,
the team must lay the tracks
930
00:52:41,926 --> 00:52:43,859
and build the trains.
931
00:52:43,861 --> 00:52:46,228
London's population
932
00:52:46,230 --> 00:52:48,764
is set to pass
nine million people in 2018,
933
00:52:48,766 --> 00:52:53,669
and they will have
a new $23 billion rail line
934
00:52:53,671 --> 00:52:56,338
to keep them on the move.
935
00:53:07,885 --> 00:53:11,587
They come from below. MedH
access.wgbh.org
936
00:53:22,900 --> 00:53:26,635
This NOVA program is available
on DVD and Blu-ray.
937
00:53:26,637 --> 00:53:31,073
To order, visit shopPBS.org,
or call 1-800-PLAY-PBS.
938
00:53:31,075 --> 00:53:34,009
NOVA is also available
for download on iTunes.