Fig. 145.—Showing the Tunnel Constructed within the Caisson.
On the concrete bed of the tunnel the segments of the metal lining were placed and surrounded by concrete, as required by the plans and specifications ([Fig. 145]). The contractors had planned to unbolt the roof from its holdings, to remove by means of dredgers the earth which had been heaped on it, and thus set the roof afloat, after which it was to be towed within the two working platforms already erected on the Bronx shore. But Mr. McBean devised a simpler and more economic, but at the same time more dangerous, way of constructing this second section of the tunnel. He thought that the upper half of the tunnel proper could be used instead of the timber roof, thereby reducing the capacity of the working chamber, and limiting the use of compressed air. In this way he dispensed with the removal of timber, and also of the earth heaped on the roof.
In building this Bronx section, a channel was dredged along the line of the tunnel to a depth of 5 ft. from the foundation-bed of the proposed tunnel. The working platforms were constructed on both sides of this channel, quite similar to those erected on the other half of the tunnel; and between them pile-bents were sunk, capped with 12-in. by 12-in. beams. Over the cap-pieces rangers were placed longitudinally, which also rested on the sides of the wooden working caisson, [Fig. 146]. The sheeting-piles were cut off at level, but much lower down than in the first half of the tunnel.
The roof was built on floats made of 12-in. by 12-in. timber laid transversely 4 ft. apart and supporting a floor of 3-in. by 12-in. planks rendered water-tight. The sides of the floats were made by verticals, 4 ins. by 6 ins., and planks, 3 ins. by 12 ins., carefully caulked. A temporary floor was built on the base of the float, consisting of transverse beams, 16 ins. by 16 ins., placed 8 ft. apart. A center piece, 10 ins. by 16 ins., was laid so as to correspond with the axis of the tunnel; and on each side of it, other parallel beams, 16 ins. by 16 ins., corresponding to each center of the circular metal lining of the tunnel; the beams, longitudinal and transversal, were strongly bolted together. The temporary floor was completed by boarding the spaces left between the various beams.
Fig. 146.—Showing Sides of the Caisson and Supports for the Roof.
On this float, the upper half of the tunnel was constructed by erecting the segments of the metal lining, which were strongly supported, so as to prevent any settling or distortion; the concrete was then built up in a large flange with vertical suspension rods, four to each bar. The rings of the tunnel were 6 ft. each, the weight of each lining being 41,000 lbs., the concrete covering 618 cubic feet. The second part of the tunnel was 300 ft. long, with roof constructed in three sections—two of 90 ft. in length each and the third of 84 ft. Each of these sections alternated with a smaller section, 12 ft. long, provided with air-locks. The shortest of the three sections was the first one set up, and was constructed close to the Bronx side of the Harlem River. For this purpose the two extreme ends of the section were closed by means of steel plates forming diaphragms, built 6 ft. inward, thus leaving one ring projecting out at each end. Openings were left on the top of these projecting rings for access by divers. The exterior of the upper half section of the permanent tunnel was filled with water until it was lowered into position. It was directed by means of tackles attached to vertical eye-bars, which were strongly fixed to the flanges of the springing line of the arch, and bolted to the beams of the temporary floor. In this way the roof was towed into place, and lowered by means of stone ballast, until it rested on the cap-pieces and frames of the pile abutments, the sides of the roof remaining just on top of the sheeting-piles that formed the sides of the caisson, as shown in [Fig. 147]. Perfect alignment was obtained by wires strung at each end and along the side of the roof, corresponding to points fixed on the working platforms and sighted with transits. Such accuracy was obtained that the circumferential flanges of the outer 6-ft. ring were brought into contact with those of the 12-ft. section already constructed. A diver then entered by the opening left in the projecting ring, and bolted this section of the roof to the preceding one. By removing the iron diaphragm, the consecutive sections were united into one. When the diver completed his work, the opening was closed up, and compressed air used to keep the water out of the box included between the roof and the temporary flooring.
Fig. 147.—Showing the Roof of the Caisson Formed by the Upper Half of the Tunnel.