Failed attempt to repair the caisson lock After the dock had become unserviceable, the naval minister requested to increase the 1849 navy budget by 20,000 guilders, so the problem could be investigated. In 1850 a dam was constructed in the wet dock for 18,827 guilders. In 1851 a budget law for 155,000 to rebuild the lock was defeated, but in 1852 the sum was granted. In 1853 and 1854 the lock of the dry dock was then rebuild for 177,366 guilders. Observations during the repairs looked very positive. When the rebuild of the lock was finished, the dam was removed, and the ship caisson put in place. However, when the pumps were started, it proved impossible to empty the dry dock further than 3.5 m below sea level. The conclusion of the failure to make the dock dry was obvious: there was a subterranean connection between the dry dock and the water outside the lock. In December 1854, a 8.40 m long screen of 12 m long piles was then driven into the ground north of the lock. A new attempt to pump the dock dry got significantly further, but revealed that a like situation existed south of the lock. So, a second screen was driven into the ground south of the lock. Another attempt to empty the dock found that this was still not sufficient. Most of the time,
Algiers had remained in the dry dock. In September 1853 she was sold for breakup while still standing in the dry dock.
Decision to build a new, larger dry dock In February 1855 a commission led by Van der Kun was then ordered to report about possible further action. The commission proposed to build a new large dry dock at the south west corner of the wet dock (Dry Dock II). Final repairs to Dry Dock I would follow after completion of the new dock. Meanwhile, the commission proposed to experiment with lengthening the screens near the Dry Dock I's ship
caisson lock. During the discussions about the 1855 budget, the Secretary for the Navy proposed to follow the advice of the new commission, which was approved. The subsequent lengthening of the screens was found to be insufficient.
Investigation (1857-1858) The budget for 1857 then got a post of 25,000 guilders for making a dam and pumping the water out of the dry dock in order to investigate the situation. In June 1857 the dock was emptied and an investigation started. It proved that water was indeed streaming under, or along the sides of the repaired lock. The findings of the commission were presented on 16 July 1857. It found that near the middle of the dock, the lower steps had been pushed up 51 cm on the north side and 62 cm on the south side. From the center to the lock side, all steps and floors had been moved out of position. Near the lock, there was an opening in the dock floor of 1.30 m long and up to 7 cm wide, which was the main leak. It led to the conclusion that the condition of the dry dock had seriously worsened since the rebuilt of the caisson lock. Another finding was that the brickwork, made by use of the mortar 'Amsterdam artificial cement' was loose in many places. The commission deemed it necessary to demolish all loose brickwork, and to remove the ballast before being able to give a sound advice. In September 1857 demolition of all loose brick work and woodwork started. On 23 February 1858 the commission was able to report that the floor of the dock on the lock side was in a terrible condition. About 30 m had been lifted from its foundation, sometimes as high as 50 cm. The space in between had been filled with sand and sea weed and the like. The inner layers of brick were solid, but those exposed to daylight were loose. Again, the bad quality of the
mortar that had been used was noted. The final conclusion was that the condition of the dock had been caused by the carelessly made and loose foundations, and the mandatory use of Amsterdam Artificial Mortar. The commission noted that contemporary limits to pump capacity would have influenced construction.
Rebuild To its 23 February 1858 report the commission also attached a preliminary design for rebuilding the dock on the existing foundations. There were two versions, one that would re-use the original caisson door, and a second plan that would require a new door. The first plan would cost 345,000 guilders, and the second 349,000. Now that the commission had found clear causes for the trouble with the drydock, it was a lot more positive about rebuilding it. On 6 August 1858, it also reported about the financial side. It said that the value of an operational dock would be 730,000, and so subtracting 349,000, the current value of the drydock was 381,000 guilders. It would therefore be unwise to build a completely new dock, for which space was lacking at Nieuwediep. The minister for the navy then vigorously promoted funding the reconstruction in the 1859 Navy budget. The House of Representatives, which had been very adverse to spending more money on Dry Dock I, was now convinced, and voted 116,000 guilders for the first year. On 17 January 1859 the required fir and oak nails for the rebuild were tendered. The initial option to re-use the first ship caisson was abandoned, because the lines of the lock would be changed, and contemporary ship caissons had a single keel, so it was not wise to re-use the first ship caisson. It was subsequently demolished. The second asymmetrical ship caisson was auctioned. On 14 March 1859 the rebuild of Willemsoord Dry Dock I was tendered, and subsequently awarded to the lowest bidder. He started work on 17 March. The contractor soon found why one the screens had not been effective: they were found to be good on top, but shattered and very open at the bottom (Fig 2, lower half). The demolition of the dock confirmed everything the commission had noted. The brickwork of the dock was removed easily. On the contrary the brickwork of the recently rebuilt lock proved to be hard, well done and solid all around. In early June 1859 the foundations had been cleared till the fir floor. Now the 'Kespen', which connected the floor to the piles, where re-attached to the piles in most places. Some piles were to deep, and their heads, were filled up to attach the 'Kesps'. This way the floor was re-attached to the foundation piles. Fixing the leakage problem near the caisson lock was a different task. For that, a concrete
coffer was built around the outside of the caisson lock. The wooden screens which had failed to stop the leakage were also replaced. Both were established on a new foundation which was prolonged to the bottom of the lock. The concrete coffer was to form one structure with the foundations of the lock. During these works, a fir floor was discovered below the kesps of the lock. In view of the leakage at this place the managers of the works decided to have it removed. Below this floor up to 1.5–2 m of ground then proved to have been washed away. Next it was found that below the southern lock walls most ground had also disappeared. The course of the water on the southern leak had now clearly been established to have followed the route (Fig. 2 line g, h, i, b). Next 332 m3 of sand was pushed below these structures using very long
pestles. Next a coffer was driven into the ground on the backside of the lock walls. In late August this was filled up with concrete (Fig. 3 fig. 1). By late August two layers of fir beams had been laid down at right angles and attached to the foundations. This fir matrix was extended from the dock into the caisson lock. The immediate objective was to make a solid attachment between the heavy foundations of the dock, and those of the lock (Figure 3). The contractor was by then so much ahead of schedule, that he started the work planned for 1860: Completing the work below the inverted arc of the drydock, completing the screenwalls to the required height (Fig. 4 Scherm- muur), and completing the concrete coffer before the dry dock. The
Formwork for the work below the inverted arc was soon made, and by late October this was finished. Filling the coffer was completed on 31 October. After the screen walls had been brought to the required height, the last steam engine that kept the works dry was stopped, and work stopped for that year. The water level in the dry dock then rose to about the same level as in the Afsluitingskanaal (see 1838 map). The only work done in winter was making the stone from the previous construction ready for re-use. Thus all work projected for 1860, had already been done in 1859. The contractor then got permission to do the 1861 work in 1860. On 23 March 1860 a steam engine then started to make the dry dock dry again. Now the southern inner wall of the lock was removed to give it the same
grade as the northern wall. The place for the ship caisson was also moved towards the wet dock as much as possible. This increased the length of the dock that could be used by ships by 7 m for special cases. If the door was in the single remaining
rabbet, usable length would be 74.5 m. If the ship caisson was pressed against the rabbet, this would become 76.75 m. In late April 1860 the masonry of the first inverted arc (fig. 3 Figuur 3 Dwarsdoorsnede, at 0.33), thick 1.5 bricks was commenced. The central sewer was also removed. In early May concrete was poured between the old and new masonry (Fig. 1, Figuur 3, l, m, n, o, i, p), till the level of the inverted arc. In places patented
Portland cement had to be added to the concrete. In late May the masonry of the second layer of the inverted arc started. It was one brick thick.(fig. 3 Figuur 3 Dwarsdoorsnede, at 0.22) This contained
eye bolts that kept the wooden blocks from floating upwards when the dock was filled. By mid-June the first part of the second layer of the inverted arc had been completed. Now the masonry of the facings of the inner lock walls was started. The northern screen wall was also heightened. In late June heightening the southern screen wall started. Construction of the lowest step also started. This was made entirely of stone and placed at the upper end of the lowest part of the second layer of the inverted arc. Next the upper part of the second layer of the inverted arc was started, as well as the brickwork for the higher steps. These higher steps would be made of brick covered with stone. Practically all the stone of the previous work was re-used. In the night of 4–5 August 1860 the dam near the land side lock (Keersluis, see 1838 map) of the wet dock was broken. It flooded the dry dock. At the end of August the wet dock, and the dry dock were dry again. By half September the masonry of the dock was completed so far, that pouring concrete between this new masonry and the old brickwork was resumed. In late October the last brick was laid. At the end of 1860 the only work left was some cleaning, and placing some large stone slabs which had not yet arrived.
The new ship caisson After it proved unfeasible to use the first ship caisson, which had been in storage for a long time, a new ship caisson was ordered. It was built according to a new model from England. It had only one keel, instead of two. It was made completely of iron, which was very useful against
Shipworms. Construction was tendered on 21 March 1860. It had to be delivered in 7 months, but bad weather caused much delay. More speed would not have mattered anyway, because the deepening of the wet dock, and the removal of the dam for the Keersluis, were not ready before Spring 1861. On 15 December 1860 the ship caisson was launched. It had balance gates to open and close a canal which led through the door towards the drydock. Iron
gate valves were made to let water into the door (Fig. 6, Figuur 4–7). To get the water out of the door again, four pumps (Fig. 6, Figuur 1–3) were present. A
locomobile of 6 hp would drive the pumps and achieve this in 22 minutes. Total weight of the door was 122,513 kg of which 103,537 kg iron. On 7 April 1861 a tugboat tugged the ship caisson from Hellevoetsluis to the North Sea, arriving in Willemsoord on 8 April. After the required ballast had been placed, she was put in place and tested. Everything worked, except for the balance gates. An attempt to repair this failed, and so the door was quite leaky. It was nevertheless taken into use as it was in October 1861.
Pumphouse II is taken into use The decision to build the new and larger Willemsoord Dry Dock II included a decision to build a new pumphouse, that would serve both docks, near Dry Dock II. A test to empty the dock failed on 22 May 1861. It was found that all tubing near the new pump building had been broken. After this was fixed, the rebuilt drydock was pumped dry on 9 September 1861. It meant that Pumphouse II was used successfully by Dry Dock I before Dry Dock got to use it. When the dock was dry, the navy started to place the blocks on the axis of the dock floor. The last attempted use of pumphouse I had been after the dam was broken in 1860, but by then sewer had already been walled up, and so the attempt had failed. The steam engine of Pumphouse I was sold in November 1860. The building was later converted to store ironware, and wheat for the naval bakery on the upper levels. In 1889 the lower levels were also converted to wheat stores. It earned it the name , meaning 'wheat storagehouse'. == In Service again (1861) ==