Bridging the Gap: How the Severn Bridge Was Built Timeshift


Bridging the Gap: How the Severn Bridge Was Built

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MUSIC: Stand By Me by Ben E King

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A quarter of a million tonnes of concrete,

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moulded by human genius and endeavour.

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A one-mile ribbon of steel forged in the white heat of technology.

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Something which put British engineering

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back on top of the world.

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The Severn Bridge is 50 years old,

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but its elegance is timeless

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and its ground-breaking design continues to be flattered

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by imitation the world over.

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This, then, is the scene set for the royal opening of the Severn Bridge.

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It is with great pleasure that I now declare the Severn Bridge open.

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The inauguration came six weeks after England had won the World Cup

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and six months after the launch of colour television -

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a time of huge national optimism.

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CHEERING

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As Her Majesty's car, leading this great procession

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on to the bridge itself,

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to make the first official crossing.

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1966 was actually a pretty great year for British design,

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for British music, for British film,

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for British fashion, for British architecture,

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for British bridge design.

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Britain was on a roll.

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Bridges have this power to transform and excite

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a community and to make people really believe

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in the power of the future, in a way,

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you know, that man's works can actually make life better.

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This is the story of the Severn Bridge,

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told by those who designed it...

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The Severn Bridge is the most perfect example

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of a suspension bridge in the world.

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It remains the leader of that sort of innovation.

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Nobody has found a way of doing it better.

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..and those who built it.

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The workforce on that bridge, they were a breed of men on their own.

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The older I get, I'm very, very proud of the job

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and everything that went into the bridge.

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But it's also the story of the men who lost their lives

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in the conquest of Britain's mightiest river.

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I always think of it as my father's.

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His bridge.

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For many of its 200 miles, the River Severn shadows

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the border between England and Wales.

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But in its lower reaches, it presents a formidable barrier

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between the two countries,

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isolating the industrial powerhouse of South Wales.

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Once, if you wanted to drive between Cardiff and Bristol,

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you faced a 100-mile journey through Gloucester and Chepstow -

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their narrow roads increasingly overwhelmed by traffic.

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Or you could take a small ferry, but it ran only in daytime

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for a handful of cars.

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The road links into South Wales from England were unbelievably awful.

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People cannot really envisage how it was.

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For instance, if you left South Wales and you went

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to the Beachley-Aust ferry, which was the way

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to get over the estuary,

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that ferry didn't always run because of the tide problems.

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And alongside the road down to the ferry

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were stakes in the ground which said,

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"Half an hour, hour, one and a half hours, two hours."

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That was how long it would take you to get into the ferry.

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And if it was about one and a half hours and you wanted to go down

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to Torquay, that was the point your father said,

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"OK, we're off."

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Up through Gloucester, down the other side.

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That gives you a flavour.

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It was unbelievably cut off.

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My name is Derek Hudd, I'm 86 years of age.

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I worked on the Old Passage Severn Ferry.

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It was quite hard work. You were on your feet most of the time.

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I, as an engineer, worked down below, on the engines.

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You were also expected to go up on deck and help load

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the boat as well, which I did. But you never minded that

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because it was good to get out of the engine room.

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There were cars, there was a queue of cars, it was fantastic.

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You could have a queue of 100 cars or more.

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There was this chap, he was up there with his children.

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And I said, "How long have you been here?"

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And he said, "Well, we got here at half past eight."

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Remember now that this was about one o'clock in the afternoon.

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And I said to him, "Well, why didn't you go around?"

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And he said, "God, I couldn't do that.

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"The kids and the missus would have gone mad."

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I used to go to stay near Chepstow.

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I used to go by ferry, this ramshackle affair,

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to get across this wide piece of water.

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It was wonderful as a child. You would arrive, go on the ferry,

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clunk across, then you got to the other side and people said,

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"You made it all right, then?"

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Like they expected that you weren't going to.

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So the arrival of the bridge was a big deal, a great expression

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of human endeavour on their doorstep.

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The Severn Bridge was greenlit in the 1940s

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to be the biggest in Britain.

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The mile-long crossing would follow the same route as the ferry.

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It would pass through an army camp and over the neighbouring River Wye

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to complete the link between England and Wales.

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My name is Michael Parsons.

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I'm 87 years old and I'm the most senior surviving design engineer

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for the superstructure of the Severn Bridge.

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This was to be the longest span bridge in the world

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outside of the United States of America.

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So it had big importance to the firms and to the government.

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And we were all conscious of the importance of what we were doing.

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I was born and brought up in Bristol, so from a very early age

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I used to go to the Clifton Suspension Bridge,

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which meant I was inspired with the whole idea of a bridge

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leaping from one side of a gorge to the other.

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The masters of long span suspension bridges were the Americans,

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and they made them big.

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The Golden Gate and the bridges of New York

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were heavyweight structures with stone towers

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supporting iron and concrete roadways.

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But when engineers tried to lighten the load, disaster struck.

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A terrifying example of the danger of vibration.

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The third longest suspension bridge in the world plunges to destruction

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at Tacoma in the United States.

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This was quite a major bridge in the United States,

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and it was a radical departure from the conventional American design.

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But the fatal flaw with that design was that it had

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virtually no torsional stiffness.

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It was too flexible.

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It wobbled itself to death, basically because there is movement,

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there is inherent movement in structures and the trouble with

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suspension bridges is that the vibration set off by the wind

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can be like a semi-perpetual state that increases and increases

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to the point where the bridge actually falls apart.

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These were big issues, but the Severn Bridge

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pioneered certain solutions to that.

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Defying the wind was the greatest challenge

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and, ultimately, the bridge's greatest claim to fame.

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A unique road design would hang from suspension cables

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draped over 450-foot steel towers.

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But before all that,

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the foundations had to be laid

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in a river infamous for the second highest tide in the world.

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Sir John, will you be faced with any particular difficulties

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bridging the Severn at this point?

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We will have to cope, of course,

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with an extremely high range of tide between high

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and low water, as much as 40 feet in this case.

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So we will be able to get to Wales in comfort by 1965?

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-I hope so, yes.

-Thank you very much, Sir John.

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I'm talking to you from the middle of the M4,

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the London to South Wales motorway.

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Or at least, it will be the middle of the M4 in 1966.

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The BBC reporter Tom Salmon documented the entire construction,

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beginning in May, 1961.

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This, in fact, is the long-awaited Severn Bridge,

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the bridge they've been talking about building now for 100 years.

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The first two years would be all about the foundations.

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On either side, enormous anchorages would counter

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the weight of the bridge and, in the river itself,

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two bases would support the towers.

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The huge tides made this the most dangerous part

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of the entire project,

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especially for the foundation of the east tower.

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I've heard a lot since I've been out here about tidal workings.

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What, in fact, does tidal working mean?

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The tide goes out and the men go down on the blocks.

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The tide comes back, and the men have to get off the blocks

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and wait for the next time.

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It's a dog-rough job and there's not many men can stick it.

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This is a picture of me with our casing sinking foreman.

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I had hair then.

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I'm John Evans.

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I was the most junior site engineer of the Severn Bridge.

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We were working in a regime where

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at a point in time of day there was 40-plus feet of water.

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Six and a half hours later, you were on exposed rock.

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Six and a half hours later, there was another 40 feet of water.

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So working in this river with this huge rise and fall

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was a major civil engineering challenge.

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The rock was probably exposed for a maximum of two hours

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at low water springs.

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So you could take a very small area, clean it off,

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and put a bit of concrete down.

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And then you'd come back 12 hours later and do another bit.

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And some of the lower parts of the rock were literally only exposed

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for about half an hour at low springs.

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I thought the men were brave because of

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the intimidation of that water coming in.

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I did feel a deep admiration for the foundation contractors.

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Because of the tides, safety launches were on permanent standby

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throughout the construction.

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The first one was skippered by a local fisherman, Jack Hollins.

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I think it's a family thing.

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My father was in the shipyard. My uncle Jack was a fisherman.

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He used to go out and fish for salmon.

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He worked on the ferry.

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He loved the water.

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As a family, we knew the river.

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We were warned about not getting in the river.

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We were frightened of it because we knew how deadly it was.

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In late '61, we heard that some men had fallen in the water

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and were drifting upstream on the flood tide.

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In the gathering dusk, one of the ferries set off upstream

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looking for these men,

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and by a marvellous set of circumstances,

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the three men were picked up

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some...mile or more above the work site.

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Jack Hollins' safety launch had joined the search,

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but when the men were rescued, he turned for home

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unaware that a tanker, the Wyresdale H,

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was heading towards him.

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We on the Wyresdale H were bound for Swansea from Sharpness.

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As I remember it, it was a very cold night.

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But all of a sudden, about 6.30pm, there was this loud crashing noise,

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and we thought, "Crikey, we've hit one of the marker posts."

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And we ran up on deck and we were shocked to see that we had hit

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a launch and the launch was smashed up between

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the two bows with one man clinging to the wreckage,

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shouting that his mate was in the water.

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We turned on the big searchlight that was mounted

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on top of the wheelhouse, trained it into the water,

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and we could see this man,

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in the water, with his hands above the water

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and his head there, and suddenly he just slipped away.

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It was just this vision of this man.

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It was as peaceful as that.

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Jack Hollins survived the collision, but his mate was lost.

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My name is Deborah Jones. I am the eldest daughter

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of John Newton, who was the first man

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to die during the building of the first Severn crossing.

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He was happy, had a lovely sense of humour.

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He was a lovely father.

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The body was never found,

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despite searching and the lifeboat going out,

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until this day, it's never been found.

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I don't think my mother said anything else,

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other than he'd jumped into the water to save somebody.

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Her way was, say nothing and just get on with it.

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And that's what she did.

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This was the first incident that had occurred on the construction site

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where serious injury or loss of life had occurred,

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and so it was quite a sobering period.

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MUSIC: Wondrous Place by Billy Fury

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Well, this is the Eastern anchorage, and this will take the whole weight

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of the Severn Bridge.

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And the next time you complain about having to lay

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a concrete path in the garden, well, just you think of this little lot.

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It's 140 feet long, 110 feet wide and 120 foot high.

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And into it, when it's finished, 90,000 tonnes of concrete,

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and 90,000 tonnes means that it will weigh more than the Queen Mary.

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The concrete consumed vast quantities of stone,

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pushing nearby quarries to the limit.

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The area's hotels were stretched to accommodate

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hundreds of workers coming in from across the country.

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But local people knew it would all help to relieve

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their biggest problem.

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Before the bridge, Chepstow had a real blockage.

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There were queues and queues and queues of people

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that couldn't get through.

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Huge lorries - they would shake the house.

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And we'd even been reduced, in very warm weather,

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to go and take drinks outside to the lorry drivers!

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There were queues every bloody day.

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Some days, it would take us bloody half a day to get to work

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with the traffic in Chepstow.

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Lorries crashing into shops and what have you.

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And it was a bottleneck.

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The famous arch in Chepstow used to be one big congestion.

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And when people drive into Chepstow, they have only one object

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at the moment, and that's to drive out of it, if they can.

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I think once the bulk of the thundering lorries

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are out of the town, people will want to come to Chepstow.

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Well, personally, I'd rather come down in the bucket.

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Well, so much, then, for the anchorage, 90,000 tonnes of it,

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45,000 tonnes still to go.

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There's another one just like it on the other side of the river,

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and they tell me there's quite a bit of rivalry between the two.

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We had to establish where the west anchorage was going to be.

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That was in the middle of the Army Apprentice College

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first rugby pitch.

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And one of the early jobs was to take up the turf

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and get rid of that.

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Lots of new lawns in Chepstow.

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Attention now switched to the base of the west tower and a new problem.

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Here, there was no bedrock on the surface,

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so to gain a solid footing, they had to dig 30 feet

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below the river and that meant installing

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temporary dams to stem the tide.

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The cofferdams themselves were, in effect, a vertical cylinder,

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40 feet high, 60 feet wide,

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and they were formed of sheet piling.

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You see it on dock walls and places like that.

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My name is Graham Nash.

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I arrived on the site of the Severn Bridge

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to supervise the construction, as a junior engineer.

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This shows the water coming in through the joints.

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The cofferdam would only leak until the tide dropped

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and then it would leak the other way.

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Then the conventional method for sealing these leaking joints

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was to pour ashes down the outside,

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and it was quite fascinating, the way in which

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the water jets just reduced away to nothing.

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So we had faith in the structure, and so once you've got faith

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in the structure, you'd put on your wet suit and your helmet

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and you'd go down there.

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We were working something like 60 or 70 feet

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below the tide level outside.

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As a ferry went past at high water, you could hear

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the thump, thump, thump of the engines and the screws.

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And sometimes, if the ferries came a little bit too close,

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you would get an extra drenching down below.

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It was an exciting job, too.

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Make no mistake, it was...

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We knew we were building something quite historical.

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The weather was also making history in 1962.

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The first inkling we had that we were in for something exceptional

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came the weekend after Christmas.

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We had the coldest spell of weather I can remember.

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Salt water in the river,

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and it became full of ice floes.

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If you were down at water level on the bank, it looked as though

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there were enough there to enable you to walk across.

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That was quite remarkable.

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Before the first snow had even looked like melting,

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in fact, while most of it was still lying where

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it had fallen, there came another and even greater blizzard.

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Again it was the south-west that bore the brunt.

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Throughout this period, we continued working

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and, towards the end of February and into March,

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the local quarries had to give up.

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The temperatures were so low that the crusher jaws,

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which were a cast-iron material, were shattering in the cold.

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Motorists were advised to take no journeys whatsoever,

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not even essential ones.

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1962 went out with the southern half of Britain

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littered with abandoned cars.

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The winter also saw the second fatal accident and it involved

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another safety launch.

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There was always a safety boat, and it was out there 24 hours a day

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so that it could go to assist, if it was needed.

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And one night, during the night shift,

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it broke away from its mooring and...

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..smashed into the pier, or one of the... I'm not quite sure what.

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It was all very sad, because we lost two people with that one.

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Both men were locals.

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One was from Bristol. The other, a father of four

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from the Forest of Dean, Albert Nelmes.

0:23:360:23:40

He was a family man.

0:23:400:23:43

He didn't have a trade apart from...

0:23:430:23:45

He started to go fishing

0:23:450:23:47

when there was not much work around in the '30s.

0:23:470:23:51

Because it was out of season,

0:23:510:23:52

and he always got a job,

0:23:520:23:54

sometimes it was building, anything he could do for the few months,

0:23:540:23:59

obviously to keep us four children.

0:23:590:24:02

I went down on that morning

0:24:020:24:04

to pick him up because we were sending some cattle to market.

0:24:040:24:10

They'd said that there had been an accident.

0:24:100:24:12

I was at school, in the sixth form, and the headmistress came in

0:24:120:24:18

and stopped the lesson and called me out,

0:24:180:24:22

and my sister was outside waiting and said that Dad was missing.

0:24:220:24:27

It wasn't until later on in that day that we were told

0:24:270:24:32

that they'd found his body in the launch, like.

0:24:320:24:36

Obviously, the tide is quite fast, running in.

0:24:390:24:43

Gone into one of the stanchions, uprights, and capsized.

0:24:460:24:50

Slowly, almost imperceptibly,

0:24:560:24:58

the sixth biggest bridge in the world takes shape.

0:24:580:25:01

Despite the setbacks,

0:25:030:25:04

the foundations were completed on schedule,

0:25:040:25:08

the anchorages on each side and the bases

0:25:080:25:11

in the river ready for the towers.

0:25:110:25:13

It was time for the concrete mixers to give way to the steel erectors.

0:25:160:25:20

It wasn't exactly exciting doing the foundations, really.

0:25:300:25:33

It was interesting but it seemed to be slow, you know.

0:25:330:25:37

It took two years to get that pier constructed

0:25:370:25:40

but once we started to erect the towers, I think then

0:25:400:25:43

it began to strike home that we were really going up.

0:25:430:25:47

A lot of people think that the towers of the bridge are made

0:25:470:25:51

of concrete, but in fact they consist of steel boxes,

0:25:510:25:55

bolted one on top of the other.

0:25:550:25:58

When you're building a suspension bridge,

0:25:580:26:00

because of the curvature of the earth, if each tower is vertical,

0:26:000:26:04

they're actually not parallel to one another,

0:26:040:26:06

because of the centre of the earth down here.

0:26:060:26:08

And believe it or not, that is allowed for.

0:26:080:26:11

If you want to get an idea of the precision of the job,

0:26:150:26:18

just consider, when the towers were completed,

0:26:180:26:21

they were strained outwards exactly 32 inches.

0:26:210:26:26

When the centre span is completed,

0:26:260:26:28

they will lean inwards exactly eight inches.

0:26:280:26:32

And when the side spans are added...

0:26:320:26:35

The towers end up vertical. Isn't that miraculous?

0:26:350:26:38

And on they went.

0:26:420:26:43

Two towers, 1,200 tonnes each, erected in eight months.

0:26:440:26:49

The next thing they had to do was to join the towers together.

0:26:520:26:55

They had to get a piece of wire across 3,000 feet of water.

0:26:550:27:00

Well, this they did quite simply by loading a huge reel

0:27:000:27:03

of wire onto a barge and driving it across

0:27:030:27:07

and paying out the wire as they went and letting it rest on the riverbed.

0:27:070:27:11

The demand for wire was insatiable,

0:27:130:27:16

the length almost enough to encircle the planet.

0:27:160:27:19

I'm Howard Peterson and I left my father's farm

0:27:200:27:25

and went to work in the winding shed.

0:27:250:27:28

I'd never seen anything like it before.

0:27:280:27:30

The machinery and the coils were starting to come in

0:27:300:27:34

and what the devil do I do with this lot?

0:27:340:27:38

They would come in on... Lorry loads was coming in.

0:27:380:27:41

You'd cut the bands on these coils and it could fly anywhere

0:27:410:27:46

if you didn't have it under control

0:27:460:27:48

and then reel it on to the main drum which was like a giant cotton reel.

0:27:480:27:53

The big drum was off-loaded and taken away

0:27:530:27:56

ready for spinning across the bridge.

0:27:560:27:59

And the foreman came to me one day, and he says,

0:27:590:28:02

"Got another job for you. I want you to go

0:28:020:28:06

"and you'll be labourer to the carpenter."

0:28:060:28:09

That was the first time I'd been up the tower.

0:28:130:28:16

They then put square pieces of steel mesh

0:28:160:28:20

to make foot-walks from one side to the other.

0:28:200:28:24

To look around and see for miles and then you'd think,

0:28:240:28:29

"God, I'm about 450 foot up.

0:28:290:28:33

"I've never been up this high before."

0:28:330:28:36

And I looked over the side then, and had a look down and see

0:28:360:28:40

the safety launch and all below and it was like...

0:28:400:28:45

Like dots down below. Unbelievable.

0:28:450:28:48

You'd go to the handrail, and one time the handrail wasn't there.

0:28:480:28:52

It would have been open. Men were working on the top

0:28:520:28:55

of this structure, putting...

0:28:550:28:57

And they had to work right on the edge of this structure.

0:28:570:29:00

They put the handrails around.

0:29:000:29:02

You can't envisage being in that situation.

0:29:020:29:05

The first wires were there simply to support the catwalks.

0:29:100:29:15

But now it was time for the main cables,

0:29:150:29:17

from which the road deck would hang.

0:29:170:29:20

And they were a different matter altogether.

0:29:200:29:23

And I think this is just about the finest argument

0:29:280:29:31

I've ever heard for giving up smoking.

0:29:310:29:33

And this is one of the main cables of the bridge,

0:29:350:29:39

looking rather more substantial up here than it does from down below.

0:29:390:29:43

And this, I suppose, to the layman,

0:29:430:29:45

is just about the most baffling bit there is of bridge building.

0:29:450:29:49

How do they get a cable as massive as this one across the river?

0:29:490:29:53

It's going now.

0:29:530:29:55

It's a process, whereby you pull a loop of this up over the towers,

0:29:550:30:02

across the main span, up over the other tower

0:30:020:30:05

and down to the far anchorage.

0:30:050:30:07

And then the carrying device

0:30:070:30:09

comes back with a loop of wire again

0:30:090:30:14

and it goes back and forward, back and forward.

0:30:140:30:17

Cable spinning, as it was known, was relentless.

0:30:170:30:21

16 hours a day for six months

0:30:210:30:23

until 18,000 miles of wire had been spun across the river.

0:30:230:30:28

All rights, Rob? Tether that up.

0:30:280:30:31

And for the whole six months,

0:30:310:30:33

only strong winds gave the steel erectors any respite.

0:30:330:30:37

Food and drink was brought to them on the catwalks

0:30:370:30:40

as the spinning went on.

0:30:400:30:42

I'm Brian Hughes and I worked on the Severn Bridge,

0:30:440:30:47

supplying the men that were spinning the cable with tea and soup.

0:30:470:30:52

My job actually was delivering the tea down to the men on

0:30:530:30:57

the catwalk. It takes about half an hour to

0:30:570:31:00

walk down there and back. With the tea on your back, mind.

0:31:000:31:04

But it was all right.

0:31:050:31:08

They were God.

0:31:080:31:10

Everything a steel erector wanted, he had to have.

0:31:100:31:13

And if a steel erector was unhappy, you'd be for the high jump!

0:31:130:31:17

Our tearoom was bolted to the side of the tower

0:31:180:31:23

and you'd enter through the roof, like, go down

0:31:230:31:26

the ladder, just like going into a submarine.

0:31:260:31:29

And towers was moving...

0:31:290:31:33

easy, could fall eight foot from side to side.

0:31:330:31:36

Cos when you was in that canteen, down by the side of the what's-his-name,

0:31:360:31:40

you put a cup under the table, he'd moved from one side back to the other.

0:31:400:31:45

Even a full cup of tea, mind.

0:31:450:31:46

When the weather was bad and the guys had to come in...

0:31:480:31:52

..I suppose they wore out more packs of cards than

0:31:530:31:57

any other industry I know!

0:31:570:31:59

The sound of the pulleys pulling the wires across was very distinctive.

0:32:020:32:09

It was a sort of tinkling,

0:32:090:32:11

clanking noise and you could hear this going on

0:32:110:32:15

from early in the morning until late in the evening.

0:32:150:32:18

Spinning continued day and night through the summer of 1964.

0:32:190:32:25

It became a way of life.

0:32:250:32:26

The team were very keen on skittles.

0:32:290:32:33

And we became interested in the possibility of competing

0:32:330:32:36

with some teams from Chepstow.

0:32:360:32:38

Once or twice we drove around the top and down to Chepstow and

0:32:380:32:41

that meant a very late return home at the end

0:32:410:32:43

of the evening. And then someone said,

0:32:430:32:46

"Well, why don't we walk across?"

0:32:460:32:47

The lights are always on. They're always safe and so we used to

0:32:470:32:52

walk across and have our skittles

0:32:520:32:54

and then have a beer and walk back again.

0:32:540:32:56

It was a very good way of spending an evening.

0:32:560:32:59

On the deck,

0:33:050:33:07

on the top of the towers, it was...portable loos.

0:33:070:33:11

We had a guy there that looked after the loos.

0:33:120:33:14

And he stunk that much, we wouldn't let him in our tea hut

0:33:170:33:21

so we used to bolt the hatch down.

0:33:210:33:23

I don't know what possessed the man.

0:33:260:33:28

He came to empty the toilets

0:33:280:33:31

and threw the bucket of waste over the side

0:33:310:33:35

and didn't even look to see where it was going to land.

0:33:350:33:39

And, unfortunately, the safety launch.

0:33:390:33:43

Beautiful day, the sun was shining

0:33:430:33:45

and we heard a splitter splutter, which sounded like heavy rain.

0:33:450:33:50

I went out of the wheelhouse and found

0:33:500:33:52

that somebody had tipped the contents of the chemical toilet

0:33:520:33:58

and most of it had landed on us.

0:33:580:34:00

The gaffer came rearing into the...

0:34:000:34:04

to the tea hut and gave us boys a real dressing down

0:34:040:34:10

about throwing the bucket of waste over the side of the bridge

0:34:100:34:14

and we said, "Well, it wasn't us. You'd better go and examine

0:34:140:34:18

"what the contents are and you can see it wasn't our fault."

0:34:180:34:23

And one of the steel erectors slapped me on

0:34:230:34:25

the shoulder and said, "It must be your lucky day.

0:34:250:34:28

"What are you backing on the horses?"

0:34:280:34:30

Once all the wires are in position, they are

0:34:470:34:49

compressed into a circle...

0:34:490:34:51

..and clamped together at a controlled tension. Each cable is

0:34:540:34:57

now ready to take a load of 10,000 tonnes

0:34:570:35:00

and the equation is almost complete.

0:35:000:35:03

MUSIC: Girl From Ipanema

0:35:060:35:08

The final stage of construction

0:35:090:35:11

was where the Severn Bridge achieved its greatest innovation.

0:35:110:35:14

Today, the old shipyard in Chepstow shows little sign

0:35:170:35:21

of its ground-breaking role in civil engineering history

0:35:210:35:24

but this was where they built the bridge's revolutionary roadway.

0:35:240:35:29

This was the first time a box structure had been made

0:35:310:35:34

of this shape or this size.

0:35:340:35:36

It was built from stiffened plates.

0:35:360:35:38

One, two, three, four, five and we all knew this was

0:35:380:35:44

an innovation and I think we all wanted to make a success of it.

0:35:440:35:48

Well, I could describe it as a spaceship.

0:35:480:35:51

The wind coming up the river,

0:35:510:35:54

they were designed for it to go underneath

0:35:540:35:57

and up and over, so it was an aeroplane shape, really.

0:35:570:36:04

Well, you know, I do believe I'm...

0:36:050:36:07

There. It looks like

0:36:070:36:09

we're discussing whether it's time to go for lunch!

0:36:090:36:12

The plated box design was a response to

0:36:140:36:16

the Tacoma disaster in 1940.

0:36:160:36:20

But it took 20 years for the idea to gain favour.

0:36:200:36:24

Those winds had sent shock waves through the world of

0:36:240:36:27

civil engineering.

0:36:270:36:28

Fortunately, the only casualties were a car stalled on the bridge

0:36:290:36:32

and a dog.

0:36:320:36:34

As a result of the failure, we in this country decided

0:36:340:36:38

that we would have to

0:36:380:36:41

stick to the open truss,

0:36:410:36:44

as in all previous American big bridges.

0:36:440:36:46

The classic American truss deck

0:36:480:36:51

comprised a heavyweight lattice of steel girders

0:36:510:36:54

under a concrete roadway.

0:36:540:36:55

And right up to the start of the Severn Bridge construction,

0:36:550:36:58

this was the plan that was being fine-tuned in the wind tunnel.

0:36:580:37:02

But the design team led by a taciturn Welshman called

0:37:040:37:07

Gilbert Roberts already had the plated box in mind.

0:37:070:37:11

They just hadn't had the time or opportunity to test it.

0:37:110:37:15

A very good solution had been found

0:37:150:37:18

to the problem of the Tacoman errors by making it

0:37:180:37:21

with openwork trusses.

0:37:210:37:24

As the wind stream meets the front girder, it divides

0:37:240:37:28

and curls round the top and bottom edges of the girder.

0:37:280:37:32

But this had the cost of considerably

0:37:320:37:35

increasing the actual ordinary wind forces.

0:37:350:37:38

And the way to get round that would be to

0:37:400:37:42

make them much more like an aircraft wing.

0:37:420:37:45

And Gilbert Roberts wanted to test the new aerofoil

0:37:460:37:50

type deck. This was unprecedented

0:37:500:37:54

and wind tunnel testing time is scarce and expensive.

0:37:540:37:59

And then one day, Gilbert came over into my...

0:37:590:38:04

into the office and said the model they were testing

0:38:040:38:07

in the wind tunnel has broken loose from its anchorages

0:38:070:38:12

and has smashed itself.

0:38:120:38:14

The man responsible was seriously worried and

0:38:140:38:17

thought that Roberts would be highly critical.

0:38:170:38:20

"I'm dreadfully sorry, Mr Roberts, but

0:38:200:38:22

"we've just broken the model."

0:38:220:38:24

And it wasn't in Roberts's nature to say, "Hurray!"

0:38:250:38:29

But that was his reaction, in fact.

0:38:290:38:31

So I said, "Well, the time has come, I think, sir..."

0:38:320:38:37

He was sir to me.

0:38:370:38:39

"I think the time has come, sir, that we've got

0:38:390:38:41

"to think about the possibility of using the plated box."

0:38:410:38:47

So out went the heavyweight truss

0:38:490:38:51

and in came the plated box, a third of the depth and half the weight.

0:38:510:38:56

It sailed through its tests and went quickly into construction,

0:39:030:39:07

a stroke of genius with a touch of serendipity.

0:39:070:39:10

It was streamlined, which meant that the wind forces were less.

0:39:170:39:22

It used less steel and therefore it weighed less

0:39:230:39:27

and therefore, you've reduced both the lateral forces

0:39:270:39:29

and the vertical forces so there were savings on

0:39:290:39:32

the cables, on the towers and on the anchorages,

0:39:320:39:36

because the tension of the cables was less.

0:39:360:39:39

And if you add all those savings together, it's immense.

0:39:390:39:43

One of the towers of one of the big

0:39:430:39:45

American bridges contained more steel

0:39:450:39:49

than the whole of the Severn Bridge.

0:39:490:39:52

And, you know, I think, when this was pointed out

0:39:540:39:56

to the American engineers, they got a bit annoyed, really,

0:39:560:40:00

and thought that we'd been cheating.

0:40:000:40:02

The Americans might have envied another benefit

0:40:030:40:06

of the boxes - that they could float and

0:40:060:40:09

therefore be towed down to the bridge.

0:40:090:40:12

The first of 88 that would span the Severn was launched

0:40:120:40:15

in September 1964.

0:40:150:40:17

All the dignitaries were

0:40:190:40:21

watching and already on the sides and he had to

0:40:210:40:24

blow, give it a blow with a hammer

0:40:240:40:27

and the pin flew up, hit the hammer out of his hand,

0:40:270:40:30

up in the air, caused quite a lot of amusement

0:40:300:40:34

but slowly, the unit started up

0:40:340:40:37

and slowly launched itself into the river.

0:40:370:40:41

And no problems, all perfect,

0:40:410:40:43

much to our delight and relief!

0:40:430:40:46

Slender, streamlined,

0:40:560:40:57

almost fragile looking, their appearance

0:40:570:41:00

conceals a strength and solidity which will

0:41:000:41:02

allow winds of 100mph to blow harmlessly around them.

0:41:020:41:05

The road sections of the bridge

0:41:060:41:08

are made of steel - in fact, they really are

0:41:080:41:10

just a series of steel boxes which have been

0:41:100:41:12

made up in the steelyard at Chepstow and then

0:41:120:41:15

launched into the River Wye down a slipway.

0:41:150:41:17

A special barge was built to collect the boxes and

0:41:190:41:22

take them to the bridge.

0:41:220:41:24

Called the Severn Knave,

0:41:240:41:25

it had no rudder and was steered by four outboard

0:41:250:41:28

engines, one on each corner.

0:41:280:41:30

My name is John Roberts.

0:41:330:41:36

I was a deckhand on the Severn Knave in 1964.

0:41:360:41:39

We were just waiting for the sections to come into the water

0:41:410:41:45

and then we'd get hold of it and secure it.

0:41:450:41:48

It was a very nice job to work on.

0:41:480:41:50

We used to look at each other and say, "They pay us for this!"

0:41:500:41:54

The skipper of the Severn Knave was Jack Hollins,

0:41:570:42:01

the man who'd survived the fatal accident on the first

0:42:010:42:04

safety launch in 1961.

0:42:040:42:06

Now, his knowledge of the river would prove invaluable.

0:42:060:42:10

Jack had always worked on the river.

0:42:110:42:14

He was a fisherman, operated one of the boats in the Wye.

0:42:140:42:19

Very skilful. He was just always in control.

0:42:190:42:24

He used to see things before they happened.

0:42:240:42:29

Jack was tall, dark and handsome

0:42:300:42:32

and he was always part of our lives as children.

0:42:320:42:36

And we used to go and stand at the end of Raglan Way

0:42:360:42:39

and we look down on the Wye River and it was

0:42:390:42:43

something to see, it was like looking at a submarine, actually.

0:42:430:42:46

Very large, wide submarine.

0:42:460:42:48

The main part of the road decking,

0:42:500:42:51

as they call it, is 80 feet wide and there will be

0:42:510:42:54

four traffic lines 12 feet wide, two in each direction.

0:42:540:42:57

All the sections for Severn were bought down the Wye

0:42:580:43:03

past our construction work and then we would

0:43:030:43:07

go round to Beachley Point and watch the work

0:43:070:43:10

of lifting the Severn units.

0:43:100:43:14

To form the roadway, the 88 boxes had to be hoisted into

0:43:150:43:19

position, a job demanding patience and seamanship.

0:43:190:43:22

INDISTINCT RADIO CHATTER

0:43:220:43:24

The tide doesn't run truly

0:43:260:43:28

underneath the bridge. You can get sections and

0:43:280:43:31

you can get parts of it where it's running upstream

0:43:310:43:35

and another part where it is running downstream, both at the same time.

0:43:350:43:39

So Jack had to manoeuvre this vessel into position

0:43:410:43:46

underneath the lifting tackle

0:43:460:43:48

and it would've been a fairly tricky job to do.

0:43:480:43:51

INDISTINCT RADIO CHATTER

0:43:530:43:55

We'd get the sections,

0:43:580:44:00

bring them out into the Severn, drop anchor, 50 yards,

0:44:000:44:06

100 yards before the bridge and then you'd let it out

0:44:060:44:09

on the winch, and just drop it down under the bridge.

0:44:090:44:12

You've got to have good visibility.

0:44:120:44:14

You've got to have wind less than 30 knots and

0:44:140:44:17

preferably no snow and ice.

0:44:170:44:19

They also needed particular tides, which meant it would take

0:44:250:44:29

18 months to complete the task.

0:44:290:44:31

I don't think there was any other skipper around that

0:44:330:44:35

could have done it myself.

0:44:350:44:36

I don't know, but I had a lot of respect for him.

0:44:380:44:41

When you're building a suspension bridge, the classic way

0:44:440:44:47

was to start at the towers and work both

0:44:470:44:50

into the side spans and then into the main span

0:44:500:44:53

whereas at Severn, the first boxes were lifted in the middle.

0:44:530:44:57

And immediately, you began to see what a huge structure

0:44:570:45:02

it was going to be.

0:45:020:45:04

So then just behind me, the winches

0:45:040:45:06

which are used to winch and hoist the main

0:45:060:45:09

road sections into position, and if you walk

0:45:090:45:11

to the very edge of the tower and look over,

0:45:110:45:14

you can see the sections of the roadway or decking

0:45:140:45:17

as they call it, that have already been hoisted into place.

0:45:170:45:20

And of course, the ferries

0:45:200:45:22

used to pass underneath the works so everybody

0:45:220:45:25

could see what was going on.

0:45:250:45:28

And it generated huge interest locally.

0:45:280:45:31

MUSIC: The Times They Are A-Changin' by Bob Dylan

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# Come gather around, people

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# Wherever you roam

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# And admit that the waters

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# Around you have grown

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# And accept it that soon

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# You'll be drenched to the bone

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# If your time to you is worth saving

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# Then you better start swimming or you'll sink like a stone

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# For the times, they are a-changing. #

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There's a lovely moment

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in the story of the evolution of the Severn Bridge

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when none other than Bob Dylan, one of the greatest stars of the day,

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turns up. Barry Feinstein took this wonderful photograph

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where you see Bob Dylan in shades looking very cool

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but what's exciting, I think, is the fact that

0:46:190:46:22

this was the very tour that Bob Dylan changed

0:46:220:46:25

from his acoustic set to playing electric.

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He was changing. The times, in his own words, were a-changing

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and there is Bob Dylan, standing at this very moment

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of great change in British culture,

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popular culture and, of course, how remarkably,

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in civil engineering too.

0:46:430:46:45

# The times they are a-changin'. #

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I remember the bridge was being built.

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It was a sight to see, of course,

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and this been has a memory I've carried with me. The understanding

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that bridges have this power to transform and excite

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a community and to make people really

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believe in the power of the future, in a way,

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that man's works can actually make life better.

0:47:090:47:12

For a year, the roadway spread slowly to

0:47:170:47:20

the east and west. But before the crossing

0:47:200:47:23

could be completed, there was another setback.

0:47:230:47:26

I just got a message on the weekend

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that Jack was dead. Simple as that.

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It was just a normal day. He was in the garden and

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Jack got stung by a bee and because the traffic

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was stopped, he was unfortunate that the doctor had to run,

0:47:490:47:53

couldn't get to him in time to give him the injection

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and he died in the garden.

0:47:570:47:58

Disbelief. Disbelief.

0:48:000:48:03

He'd survived all sorts of things and to die from a rather

0:48:050:48:09

paltry thing like a bee sting was just unbelievable.

0:48:090:48:12

But that's when his luck ran out.

0:48:120:48:15

We didn't know what they would do, the bridge builders,

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or whatever.

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So I ended up in charge of the Severn Knave.

0:48:220:48:27

BIRDS CAW

0:48:300:48:31

March the 1st 1966, St David's Day.

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And the last section of roadway to go in.

0:48:440:48:46

The last section was at Beachley on St David's Day.

0:48:500:48:53

Just drove it around on the engines with the anchor secure.

0:48:530:48:57

When it was in position, it was hoisted up the river.

0:48:570:49:01

I think the man who designed and built the bridge,

0:49:030:49:07

very, very clever.

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How everything fitted, everything went together, everything

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come together smoothly.

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That was the end of the job.

0:49:170:49:19

But it was a good job.

0:49:220:49:24

MUSIC: Paint It Black by The Rolling Stones

0:49:280:49:30

# I see a red door and I want to paint it black

0:49:350:49:41

# No colours any more, I want them to turn black... #

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After over five years of the most advanced engineering,

0:49:470:49:52

four men on their hands and knees did the final job,

0:49:520:49:56

because no-one had yet invented a machine that

0:49:560:49:59

could tarmac the roadway.

0:49:590:50:00

# ..line of cars and they're all painted black

0:50:000:50:06

# I see people turn their heads and quickly look away... #

0:50:060:50:10

Two decades in the planning, six years in the making and

0:50:110:50:16

five months ahead of schedule,

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the Severn Bridge was fit for a queen.

0:50:180:50:21

This, then, is the scene set for the royal opening of the Severn Bridge.

0:50:250:50:30

An occasion of such importance

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that the BBC scheduled two hours of live coverage.

0:50:320:50:37

We all went across to Aust,

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where the Queen appeared and she was introduced

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to everybody, dignitaries from far and wide.

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Sir Gilbert Roberts, responsible for the design of the superstructure

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and the steelwork.

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Magnificent lady that she is.

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Mike Parsons has been working on the Severn Bridge

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on and off for 17 years.

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I was much more...almost servile in those days, faced with the Queen.

0:51:010:51:07

I see the pictures of myself, slightly bowing

0:51:070:51:11

with my hand held out.

0:51:110:51:13

And now, John Robertson.

0:51:130:51:15

He's 25 years old. He's from over in the other side, from Chepstow.

0:51:150:51:18

Met the Queen!

0:51:180:51:20

Eventually, he became skipper of the Severn Knave.

0:51:210:51:26

I was called around to Mr Hyatt's office. He thanked me

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and he said, "For what you've done, I'd like

0:51:290:51:33

"you to meet the Queen."

0:51:330:51:34

And so, the royal car

0:51:360:51:39

moves towards the eastern approach to the new Severn Bridge.

0:51:390:51:43

And down below us now,

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the klaxon horns are sounding from the boats.

0:51:510:51:55

There's something very special about seeing a very

0:51:550:51:58

light structure, especially a bridge,

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crossing a great big landscape,

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so at that point you might expect a bridge to be this

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mighty great stone or concrete construction,

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to take you safely across and what you find is

0:52:080:52:10

something very filigree and fine indeed.

0:52:100:52:13

The overwhelmingly simple fact about all this is

0:52:140:52:17

that nowhere in the world is there a bridge like this one.

0:52:170:52:20

It's the lightest for its length and strength ever built.

0:52:200:52:23

And the techniques used in its construction have

0:52:230:52:26

already been copied and will certainly continue

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to be copied, not only in this country

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but in all parts of the world.

0:52:310:52:33

The breakage of the model

0:52:340:52:36

was completely crucial, because it opened the door to testing

0:52:360:52:39

the new scheme, and the new

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scheme at that time was completely innovative

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for long span bridges.

0:52:440:52:45

And later, she is to see the Concorde.

0:52:470:52:49

Now building at the BAC's Filton factory.

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So quite a day, this, for British engineering.

0:52:530:52:57

I think as a nation at that time, we did feel supremely confident.

0:52:570:53:02

I personally felt I could do anything. I know it's ridiculous,

0:53:030:53:09

really, but everybody felt confident for the future.

0:53:090:53:14

The idea of a bridge to span

0:53:140:53:17

the Severn has been a vision for many years.

0:53:170:53:21

And as an advertisement of the ability of British

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engineers and constructors and shows

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just what can be achieved.

0:53:310:53:32

It is with great pleasure that I now declare

0:53:340:53:38

the Severn Bridge open.

0:53:380:53:39

The bridge was considered so

0:53:410:53:43

special that an orchestral piece was

0:53:430:53:45

commissioned for the occasion.

0:53:450:53:46

It was commissioned, actually, by none other than the BBC.

0:53:460:53:49

It was a work called Severn Bridge Variations,

0:53:490:53:52

written in six connecting parts by

0:53:520:53:55

three Welsh and three English composers.

0:53:550:53:58

The French had done this quite a bit over the years,

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celebrating engineering structures with modern music.

0:54:020:54:06

The British came in,

0:54:060:54:07

this Anglo-Welsh venture, rather beautiful.

0:54:070:54:11

A year after the royal opening, a second plaque was

0:54:180:54:21

unveiled to commemorate the six men who lost their lives

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in the construction of the Severn Bridge. Remarkably few, perhaps,

0:54:250:54:29

for such a perilous project.

0:54:290:54:31

In 50 years, many more of the 400 who built the bridge have

0:54:330:54:37

passed away. But those that remain

0:54:370:54:39

preserve their memories with great pride.

0:54:390:54:42

At the end of the day, we had a party and we all got

0:54:440:54:47

very merry and that was it.

0:54:470:54:49

Some years after I finished on the ferry, I thought,

0:54:510:54:54

"I'll paint a picture of the last day"

0:54:540:54:57

and I just sat down and painted this.

0:54:570:54:59

I like Raoul Dufy and I try to

0:54:590:55:02

paint like him but his paintings look very easy to do.

0:55:020:55:07

But, no, it's not easy. No, it wasn't easy to do.

0:55:070:55:10

But I just painted. I just painted it and there it is.

0:55:100:55:15

I've got shallots in the corner now, waiting,

0:55:160:55:19

when they grow up, they'll

0:55:190:55:20

be for pickled onions, for pickling.

0:55:200:55:22

Broad beans, leeks,

0:55:220:55:25

and this is the walkway from the Severn Bridge. Oh, and by the way,

0:55:250:55:29

I forgot to mention my rhubarb.

0:55:290:55:31

You can see how strong...

0:55:330:55:34

You can put all the pressure on it.

0:55:340:55:36

And it's perfect. Not a bit of rust after 50 years.

0:55:380:55:42

I think the bridge today looks just as fine as

0:55:430:55:47

what it was when it was first built.

0:55:470:55:50

I can remember flying, coming back from holiday on the flight,

0:55:500:55:53

looking down from the plane and you could see

0:55:530:55:55

the bridge, absolutely perfect.

0:55:550:55:58

That made me feel proud.

0:55:590:56:01

I'm glad we landed!

0:56:030:56:05

CREW LAUGHS

0:56:050:56:07

MUSIC: Stand By Me by Ben E King

0:56:070:56:09

It has an inherent beauty, doesn't it?

0:56:090:56:11

Between the towers, they suspended this cable which takes

0:56:110:56:14

a particularly strong characteristic form,

0:56:140:56:16

a parabolic curve and I suppose, part of the great success

0:56:160:56:20

of the Severn Bridge truly is

0:56:200:56:22

the fact it is simply beautiful. Like a great work of art.

0:56:220:56:26

It looks right to people who

0:56:260:56:28

don't know anything about engineering.

0:56:280:56:31

They can see how it works.

0:56:310:56:33

It's like hanging washing on the line, you know, you can see how

0:56:340:56:37

the washing is supported by the thin wire

0:56:370:56:42

but it is a fact that if it looks right, it's a good

0:56:420:56:45

indication that maybe you have got it right.

0:56:450:56:49

So right that the Severn Bridge design has been

0:56:490:56:52

adopted by every subsequent long span suspension bridge

0:56:520:56:56

and Mike Parsons and his team won a prestigious engineering award,

0:56:560:57:01

sharing it with the inventors of the jump jet.

0:57:010:57:03

-Are you all right?

-This is a form of

0:57:050:57:07

stability I've never investigated.

0:57:070:57:09

I received the MacRobert award as part of the prize given

0:57:090:57:14

to Freeman, Fox and Partners for the design

0:57:140:57:17

of the Severn Bridge. And this was the first one

0:57:170:57:21

that's ever been awarded

0:57:210:57:23

but I think they picked a good one to start with.

0:57:230:57:27

20 years ago, the second Severn Crossing created

0:57:300:57:33

a more direct route for the M4

0:57:330:57:35

and prompted questions about the future of the old bridge

0:57:350:57:39

that continue to this day.

0:57:390:57:42

But for the men who built it, there will only ever be one way.

0:57:420:57:45

It remains the leader of that sort of innovation.

0:57:480:57:52

Nobody has found a way of doing it better

0:57:520:57:55

and I always use the old Severn Bridge

0:57:550:57:58

whenever I have occasion to go to South Wales.

0:57:580:58:01

# Darlin', darlin', stand by me

0:58:160:58:20

# Oh, stand by me

0:58:200:58:24

# Oh, stand now

0:58:240:58:27

# Stand by me. #

0:58:270:58:29

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