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Standing on a cluster of piles at the outboard end of the Fulton Street ferry slip, John Roebling was measuring to determine precisely where the Brooklyn tower should stand. He forgot about the ferry. A boat slid into the slip, nudging the piles against the fender rack. The engineer's foot was caught and crushed. Two weeks later he was dead of gangrene from blood poisoning.
Down in Trenton, New Jersey, where he was manag- ing the family's wire-rope manufacturing firm, Colonel Washington Roebling knew what his father would want. At 32 he took over as chief engineer.
Using the newly devised caisson to reach bedrock, the workers plunged into the work of building the towers. It was maddeningly slow, with progress some- times limited to six inches a week because of the cement-like bottom hardpan. Young Roebling con. ceived the idea of blasting inside the compressed air chamber, something never before tried. First he fired several revolver shots to test his theory, then tried small explosive charges. Nothing dangerous occurred, so he went on to heavy charges.

Elevation of bridge, showing temporary ropes used in cable-making. (Harper's Magazine: May 1881)
One of his engineers said the scene in the caisson was straight out of Dante's Inferno, with half naked men moving in the dim light, the noise of hammers and drills shattering the eardrums and smoke from powder charges adding to the Stygian gloom. When Roebling switched to smokeless powder, just invented by Alfred Nobel, the work went faster. But not always smoothly. Once the caisson "blew out," again the timber roof caught fire and smoldered for weeks, and once the men managed to shut a hatch against the waters of the river just in time, but finally the Brooklyn tower rested firmly on bedrock 44-1/2 feet below the surface.
The New York tower presented more hazardous prospects. Bedrock was found seventy-eight feet down, almost twice as deep as at the other side of the river . The caisson would have to operate with a pressure of thirty-five pounds per square inch and this meant that air compression illness, commonly called "the bends," would be a ,constant enemy. And there was quicksand under the silt!
Soon workmen were seized by the horrible cramps of caisson illness. On April 12, 1872 the first worker died. The number of stricken rose until a hundred or more were unable to work. Two more sandhogs died. Then on a summer day that year they carried 35-year-old Colonel Roebling out of the caisson, paralyzed for life.
There was talk of a new chief engineer but the younger Roebling refused to quit. Taking an apartment in Brooklyn overlooking the rising towers, the engineer watched progress through field glasses. His wife, Emily, when not busy nursing her husband, learned mathematics and engineering so that she was able to understand his orders, transcribe notes, and give them to junior engineers to execute. Another great engineer, David Steinman, wrote years later that Washington Roebling was like a wounded general still directing a battle from a hilltop command post through a devoted chief of staff.
It required three more years to finish the huge piles of masonry that were the bridge towers. Then anchorage blocks were imbedded in the ground to hold the ends of the four cables. Next came the problem of spinning the cables.
Obviously, a wire cable large enough to help sup- port a bridge with its great weight plus the burden of the vehicles on it could not be lifted to the tower tops or strung across a river. It had to be fashioned, small wire by small wire, until it reached the desired strength. This means that first there must be what were called traveler ropes suspended over the river to hold flimsy platforms on which men could work bonding the wires into a cable.

Cross-section of bridge, showing the foot, rail, and carriage ways.
("Harper's Magazine:' May 1881)
In the summer of 1876 a great reel of rope was anchored at the Brooklyn end, then rolled on a reel placed on a scow. The scow was towed to the Man- hattan side, paying out rope as it went. The traveler rope sank to the river bottom, out of the way of ships and boats. Then a hoisting engine lifted the rope over the New York tower, taking up the slack until the rope emerged from the water and was pulled high in the air above the cross. Other ropes followed, but not before E. F. Farrington, chief carpenter, rode across the single strand in a boatswain's chair while thou- sands of spectators held their breath, wept or cheered. Whistles blew, bells rang, ferry boats stopped in midstream to give passengers a better view, and when Farrington touched down on the Manhattan side he was mobbed by the hysterical crowds. He had been the first across the Niagara gorge and across the Ohio. Now he was a hero in an age that could not yet dream of a John Glenn or a Neil Armstrong.

The Brooklyn pier under construction as the 39th course of masonry was completed September 21, 1872. (Museum of the City of New York)
Catwalks were built under the traveler ropes and the work 0Ł spinning the cables began. One by one, wires were drawn from the Brooklyn end on a travel. ing wheel, up the eastern tower, sinking in a graceful curve over the river, over the Manhattan tower and down to the anchorage on that side. Each wire was continuous from end to end.
From the ground or from a boat on the water, the four cables from which the bridge is suspended appear only as large black lines against the sky. But each one is made to bear an incredible load. The workmen fed the wires, one by one, across the river until they had nearly 300. Then these were tied together, without twisting, into a single strand. Each wire was gal- vanized (coated with zinc) to fight the corrosion of salt air from the ocean. Each strand was also protected. Finally nineteen strands were tied together to fash- ion one finished cable. In other words, each of the four main cables consists of about 5,700 individual steel wires.
Two years after the cable spinning began the city and nation were rocked by the exposure of fraud on the part of J. Lloyd Haigh, the wire contractor. Haigh had underbid the Roebling wire-rope company even though the chief engineer had sold his interests in the family firm so it could bid on the contract. Inspectors discovered that Haigh was taking rejected wire away from the bridge building yard, putting it in a ware- house nearby, and then carting it out again with other wire that had passed inspection. Roebling de- cided not to discard the ones already woven into strands but to force the contractor to add other wire to bring strands up to specified strength.
This furor was still white hot when a strand being fastened at the N ew York anchorage broke lose carrying its cast iron shoe and other attachments with it, and whipped up in a 900-foot arc before falling across housetops and buildings to land in the con- struction yard at the river's edge. This was not all. The energy created when part of the strand fell into the river acted like a man cracking a bullwhip and sent the strand skyward again.
This time it snaked up over the tower and plunged into the water, narrowly missing a ferryboat. Two men were killed and three injured in this bizarre accident.
Others died in less dramatic mishaps. Hammers and sledges Łell Łrom work platŁorms and killed men below. High winds blew others off catwalks, and hoists broke, letting huge chunks 0Ł granite masonry Łall to the ground.
Colonel Roebling saw some of these tragedies through his binoculars. Others he learned about in the daily reports, but with unswerving determination, he ordered the work carried on with added saŁety precautions.
He was less able to cope with financial difficulties growing out of politics and rising costs. Well before the span was ready for its roadway, expenses were running far beyond the original calculations. Promoters raised the cost of land acquisition. Subcontractors kited their bills and it became evident that the bridge would ultimately cost closer to $13 million.
Public outcry forced the bridge company out of the picture. The firm was liquidated and the two cities of Brooklyn and New York assumed fiscal responsibility for completion. In the midst of this change of control someone quarreled with the Roebling theory of extra strength. This concept had led to the placement of extra heavy steel trusses so that locomotives and heavy steel cars could eventually use the bridge. New York newspapers seized upon this aspect of the construction as an excuse to excoriate the crippled engineer in articles and editorials.
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