Twenty years before, while engaged with his father on the Thames Tunnel, he had conceived the idea of working under a diving-bell of great dimensions. Sir Isambard approved of the suggestion, and thought of applying it in sinking the shafts of the Tunnel. Drawings were prepared, but the circumstance of a patent for a similar idea having been taken out by Lord Cochrane partly deterred him from carrying out the project, though some sketches were afterwards made for constructing a lighthouse by means of this arrangement. When the construction of the Cornwall Railway had to be considered, Mr. Brunel thought that his old idea would be applicable to the difficulties to be encountered at Saltash.
Although the plan of using a large diving-bell was one which was nearly certain to be successful, Mr. Brunel thought it probable that a large cylinder of wrought iron could be constructed to serve as a coffer-dam, and that after sinking it through the mud, the bottom edge might be sufficiently water-tight to admit of the water being pumped out, and the masonry of the pier built in the ordinary manner.
A trial cylinder, 6 feet diameter and 85 feet long, was made, partly to ascertain whether or not this plan was practicable, but mainly for the purpose of thoroughly examining the site of the centre pier, where the surface of the rock was 80 feet below high water.
A strong framework was fitted on two gun-brig hulks, with powerful tackle for lowering and raising the cylinder. After it had been lowered to the bottom, five borings were taken within it, reaching through the mud to the rock. The cylinder was then shifted and similar borings made.
The positions of the borings, one hundred and seventy five in all, were carefully recorded; and thus a minute and accurate survey was obtained of the surface of the rock. The site of the pier was afterwards determined by means of a model constructed from these observations. In January 1849, when sufficient information had been obtained, the water was pumped out of the trial cylinder, and the mud excavated down to the rock. A short piece of masonry was then built, to demonstrate the practicability of building a pier in such a situation.
The expenditure of the Company for works of all kinds was shortly afterwards curtailed as much as possible, and no further progress was made for upwards of three years. However, information had been gained which proved that a masonry pier could be built in the middle of the river, on a good rock foundation which was there covered by a thickness of about 16 feet of mud.
During the suspension of the works, all the plans were revised, with the view of reducing the first cost wherever practicable; and Mr. Brunel decided not to make the bridge for a double line, even if there were money forthcoming to do so. His reason for this is given in the following report to the Board of Trade, made in 1852:—
This bridge had been always assumed to be constructed for a double line of railway as well as the rest of the line. In constructing the whole of the line at present with a single line of rails, except at certain places, the prospect of doubling it hereafter is not wholly abandoned, but with respect to the bridge it is otherwise.
It is now universally admitted that when a sufficient object is to be attained, arrangements may easily be made by which a short piece of single line can be worked without any appreciable inconvenience.... This will make a reduction of at least 100,000l.
In the summer of 1852 the designs of the bridge were matured, and by the beginning of 1853 the Admiralty had approved of them; the work of constructing the great cylinder for the centre pier was then commenced.