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narrator: a pioneering team of engineers
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is digging deep on something massive.
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now it's showtime.
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we can read you loud and clear.
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they're attempting to build an innovative
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$3.5 billion circular railway
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right underneath the heart of an historic capital city...
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starting to roll now.
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with 17 brand-new stations and 39 driverless trains.
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to build the biggest construction project in the city
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for 400 years,
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the team must battle toxic soil
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and catastrophic floods --
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and collapsing earth.
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man: time-wise, we're right on the limit.
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no, failure is not an option.
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narrator: this uniquely challenging underground railway
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ranks in a league of ambitious new engineering wonders
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that are bigger, faster, taller and more advanced
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than anything ever constructed before.
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this is the inside story of the extraordinary challenge
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of building these giants.
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-- captions by vitac -- www.vitac.com
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captions paid for by discovery communications
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♪♪
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narrator: the historic city of copenhagen
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lies on the east coast of denmark.
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its spectacular architecture and sights
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attract millions of visitors each year.
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but this creates a problem for the city's population --
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the capital's roads are congested.
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copenhagen's 1.2 million residents
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have to battle constant gridlock
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that blocks major roadways.
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the city does have a metro, but, built in 2002,
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it was not designed to cope with today's peak demand.
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so that's why, in 2011,
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beneath the center of this historic city,
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this team of engineers begins building
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a trailblazing new underground railway.
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man: it's pretty challenging and an important project
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because it is supposed to get 90 percent
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of the population of copenhagen.
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narrator: constructed in a circle underneath the city,
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the new railway, called cityringen,
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will bring the majority of the population
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within a 10-minute walk to a station,
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doubling the metro's capacity.
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the man tasked with constructing
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the railway's congestion-busting tunnels
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is valerio violo.
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violo: the city of copenhagen is looking at us.
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it is following the progress of the construction
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now on a daily basis.
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they really want us to finish
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and to get the metro up and going,
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so that's kind of a strong pressure on our shoulders.
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narrator: building a project of this magnitude
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directly beneath the heart of this historic capital
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is no simple task.
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man: there are a lot of safety challenges from underground
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works that come together, provides us with a lot of risk
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and hazard that you don't normally get
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in the normal construction of a building, for example.
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narrator: in just eight years, this is the massive railway
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valerio and the copenhagen metro team must somehow build.
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the plan is to construct 17 brand-new subterranean stations
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that will circle the city in a ring.
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each station will be unique,
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built to reflect its surrounding area.
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underground, at track level,
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platform edge doors will separate commuters
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from the 19 miles of freshly dug tunnels
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that will transport commuters around the city in minutes.
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39 innovative driverless trains
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will run through the tunnels.
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♪♪
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each train will have the capacity
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to shuttle 280 passengers
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between stations every 90 seconds.
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the new metro will be able to transport
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around 70 million passengers a year when it's complete.
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♪♪
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man: it's going to be a big challenge
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because the city itself is relatively small and congested,
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so there are challenges ahead, challenges
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that everybody is willing to take on onboard and face.
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narrator: building the vast underground metro
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in this jam-packed capital city
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involves a series of key challenges.
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the team needs to excavate 17 massive holes
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right in the heart of the city.
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inside them, they will build the sunken stations.
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to connect up each station, valerio and his team
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must excavate three million tons of earth
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to create the two circular tunnels for the trains.
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hot on the heels of the tunnelers,
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a team of track layers must position,
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concrete and weld together over 19 miles of rail track.
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engineers must also construct and test
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the fleet of 39 new driverless trains.
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one of the team's greatest challenges
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will be to construct a stretch of tunnels
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that must pass directly underneath copenhagen's
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historic central train station
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while it remains open.
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♪♪
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the first task is to construct the tunnels.
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these must be built before work
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inside the stations can continue.
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we have 36 months to complete the tunneling.
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there is always the possibility to make a mistake in tunneling,
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and we need to be focused and to maintain our concentration.
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narrator: as the son of a geologist,
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valerio is no stranger to the underground.
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he has over 21 years' experience on mining projects
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around the world,
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but the cityringen tunnels pose his biggest challenge to date.
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violo: i never had such a big project to manage
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and such a big company to manage all by myself.
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this one was a pretty challenging task.
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[ foreign ]
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narrator: to excavate the 19 miles of tunnels on time,
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the team is using a fleet of innovative
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digging vehicles called tunnel boring machines,
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or tbms for short.
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violo: we had four machines working at the same time
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this month under copenhagen.
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narrator: each tbm is 344 feet long
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and is a mobile tunnel-building factory.
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at the front, a giant 19-foot rotating cutter head
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claws away at the earth.
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the excavated material moves away from the cutter head
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on a conveyor.
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it is loaded into carts for a small train to tow away.
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a robot arm installs precast concrete segments
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to line the freshly dug tunnel tubes.
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it takes six segments to make up a complete tunnel ring
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4.6 feet wide.
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hydraulic pistons then push the machine forward
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so the excavation process can begin again.
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on average, each tunnel digging machine
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can install 18 rings a day as it snakes its way under the city.
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tunnelers have been digging
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copenhagen's tricky sea-level geology
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nonstop since 2013.
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the machines claw away up to 3,000 tons
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of earth, sand and super-hard rock every day.
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they dig out and line an average of 3.7 miles of tunnel per year,
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but this is a crucial day for the tunneling team.
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one of the four machines is burrowing its way north
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to what will eventually become trianglen station.
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now it must break through
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into the half-built station structure itself
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so that the tunnels and stations connect.
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claudio ramazzini is in charge
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of this critical part of the operation.
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man: this is the breaking side of the station.
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basically, as you can see here,
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here we have the concrete block,
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and inside of this concrete block,
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we have one of our big tunnel-boring machine,
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and it's about to get in the station.
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♪♪
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narrator: but that's easier said than done.
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to prepare for the machine's breakthrough,
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engineers have built a giant concrete block
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at the precise point where it will enter.
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the block acts as a plug to stop earth and groundwater
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flowing into the station as the machine eases through.
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without this block,
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the pressure from the surrounding water in the ground
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could cause the wall around the machine to collapse,
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creating catastrophic damage,
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but already this worst-case scenario is becoming a reality.
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narrator: in copenhagen, engineers are busy building
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the city's biggest construction project in 400 years,
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the $3.5 billion cityringen metro.
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at the moment, the tunnel-boring machine
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is about 35 feet behind the block.
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if you get closer to the wall, you can hear the noise
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of the cutter head cutting the concrete.
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narrator: for claudio and the team,
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the stakes are high.
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we have to do the breaking on time to stay on schedule,
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so the teams here in trianglen station
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can finish building the station.
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narrator: paul evans heads down to make the final checks.
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man: some of the concerns we have when the actual tbm
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literally breaks through that concrete
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is the possibility of debris
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flying quite a distance and injuring people.
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narrator: but, with the tunneling machine
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now just 16 feet away from breaking through,
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the team hits a problem.
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[ foreign ]
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groundwater starts flooding into the station
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through a gap in the top of the concrete block,
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threatening the entire project.
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we have a problem here of water inflow,
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so we had to stop the excavation.
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we need to get this fixed quickly
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so that we can proceed with the breakthrough operations.
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we don't want delay.
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narrator: groundwater is flowing through a gap
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between the outer edge of the tunnel
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and the platform ceiling.
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unstopped, it could catastrophically flood
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the tunnels.
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to stem the flow, valerio's team must drill a ring of holes
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through the tunnel segments.
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the holes need to be at the precise points
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where the tunnel meets the stations exterior wall.
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then they'll inject a special type of resin
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through these holes.
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the resin solidifies on contact with water
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and should form a watertight seal around the tunnel
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to plug the leak.
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♪♪
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inside, the station engineers begin battling the floodwater.
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♪♪
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narrator: it takes a frantic few days
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working around the clock
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to inject the resin
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and make the station watertight.
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with the leak fixed, and with just over two feet to go,
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the team prepares to break through,
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hoping the resin plug holds.
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narrator: the station team gathers
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to witness the milestone.
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it's an anxious time for workers.
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i've been waiting for 4 years for this machine
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to arrive on this side.
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♪♪
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okay. now i'm going to call the pilot and say to him,
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"restart and break in."
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finish. no more delays.
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♪♪
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this is the moment of the truth.
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♪♪
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♪♪
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i'm very happy now because we are
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with the tunnel boring machine.
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we have done the break-in, so...
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great moment.
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yeah!
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narrator: success --
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the tunneling team breaks through
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and joins up with the station crew for the first time.
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[ cheering ]
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but for claudio, the hard work doesn't stop here.
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ramazzini: all of the pressure gone now,
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just for a few hours,
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and then, again, pressure
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because we have to push the tunnel boring machine
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on the other side of the station.
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♪♪
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narrator: with the tricky breakthrough behind them,
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the four tbms pick up the pace.
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i can set this to... fifty percent.
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yes.
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narrator: the machines chew through
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nearly 3,000 tons of dirt and stone
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every day as they burrow underneath the city.
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but getting rid of all this excavated earth
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is another huge challenge for valerio's team.
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violo: the tbm can build a lot of rings per day.
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now considering the distance,
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we are doing 18 rings per day on average.
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00:15:27,020 --> 00:15:29,490
narrator: after the machine builds each ring,
271
00:15:29,490 --> 00:15:32,690
the excavated earth is carried away from the cutter head
272
00:15:32,690 --> 00:15:36,700
and dumped into a series of carts.
273
00:15:36,700 --> 00:15:40,500
once full, a small train pulls them out to be emptied.
274
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♪♪
275
00:15:44,170 --> 00:15:46,240
any delay of getting rid of the waste
276
00:15:46,240 --> 00:15:48,470
could hold up the entire project.
277
00:16:03,990 --> 00:16:05,990
narrator: but copenhagen's unique geology
278
00:16:05,990 --> 00:16:07,590
creates a problem.
279
00:16:17,210 --> 00:16:19,470
narrator: an old industrial part of the city
280
00:16:19,470 --> 00:16:23,010
has left behind a toxic legacy.
281
00:16:23,010 --> 00:16:26,010
this makes the task of managing the excavated earth
282
00:16:26,010 --> 00:16:27,480
even tougher.
283
00:16:27,480 --> 00:16:30,380
i'm taking some samples to be sent off for lab testing.
284
00:16:33,760 --> 00:16:37,020
narrator: every day, christian's team must sample
285
00:16:37,030 --> 00:16:40,290
a trainload of muck for traces of contaminants,
286
00:16:40,290 --> 00:16:44,160
but he can't afford to hold up tunneling.
287
00:16:44,170 --> 00:16:46,100
these samples, together with the muck,
288
00:16:46,100 --> 00:16:51,300
sent for analysis every day while the tbm is mining.
289
00:16:51,310 --> 00:16:53,040
narrator: workers empty the dirt and rubble
290
00:16:53,040 --> 00:16:55,510
from these carts into temporary pits
291
00:16:55,510 --> 00:16:57,580
while they wait for the test results.
292
00:16:57,580 --> 00:17:02,050
♪♪
293
00:17:02,050 --> 00:17:04,580
tjustrup: every day, we get the decisions from the authorities,
294
00:17:04,590 --> 00:17:07,920
and then we instruct the work site manager
295
00:17:07,920 --> 00:17:10,790
how they should organize the deposit
296
00:17:10,790 --> 00:17:12,590
and which muck pit is clean
297
00:17:12,590 --> 00:17:14,990
and which muck pit is contaminated.
298
00:17:15,000 --> 00:17:16,460
narrator: it takes 24 hours
299
00:17:16,460 --> 00:17:18,800
for the result of each test to come through.
300
00:17:20,800 --> 00:17:23,740
the team anxiously awaits the results.
301
00:17:36,480 --> 00:17:38,550
narrator: engineers are busy tunneling
302
00:17:38,550 --> 00:17:40,550
underneath the city of copenhagen
303
00:17:40,560 --> 00:17:43,220
to create a massive new subway,
304
00:17:43,220 --> 00:17:46,830
but they must find out if the soil is toxic.
305
00:17:46,830 --> 00:17:48,290
-hi, klaus. -hi.
306
00:17:48,300 --> 00:17:49,430
where is the muck going today?
307
00:17:49,430 --> 00:17:50,960
is it clean? it's clean muck.
308
00:17:50,970 --> 00:17:52,700
okay. thank you very much.
309
00:17:52,700 --> 00:17:54,630
all the muck today is clean,
310
00:17:54,640 --> 00:17:58,300
and it's going to be disposed of to the clean soil facility.
311
00:17:58,310 --> 00:18:05,310
♪♪
312
00:18:05,310 --> 00:18:07,980
maybe the situation is different tomorrow.
313
00:18:07,980 --> 00:18:11,450
we'll have to wait and see.
314
00:18:11,450 --> 00:18:13,190
narrator: each truckload of muck
315
00:18:13,190 --> 00:18:15,190
travels five miles north of the city
316
00:18:15,190 --> 00:18:16,920
to this unique facility.
317
00:18:16,920 --> 00:18:20,790
♪♪
318
00:18:20,800 --> 00:18:23,860
this is no ordinary waste dump.
319
00:18:23,870 --> 00:18:26,270
workers here are using the clean coil
320
00:18:26,270 --> 00:18:30,470
to extend the city out into the sea.
321
00:18:30,470 --> 00:18:32,540
they're filling in an area of the waterfront
322
00:18:32,540 --> 00:18:35,140
over a half square mile to create space
323
00:18:35,140 --> 00:18:39,350
for a new port and park land.
324
00:18:39,350 --> 00:18:42,350
tjustrup: the area is going to increase the area of copenhagen
325
00:18:42,350 --> 00:18:43,880
by one percent.
326
00:18:43,890 --> 00:18:45,890
the total area where we are right now
327
00:18:45,890 --> 00:18:48,820
is going to be used for the public in copenhagen,
328
00:18:48,820 --> 00:18:50,960
for fishing, for having picnics
329
00:18:50,960 --> 00:18:52,630
and for doing some kind of playing
330
00:18:52,630 --> 00:18:54,490
and whatever people like to do.
331
00:18:54,500 --> 00:18:55,830
today it's a bit cold.
332
00:18:55,830 --> 00:18:58,230
i'm freezing, but when the summer is coming,
333
00:18:58,230 --> 00:19:00,370
maybe we can take a swim in the sea
334
00:19:00,370 --> 00:19:02,440
and do some sunbathing.
335
00:19:02,440 --> 00:19:05,740
♪♪
336
00:19:08,710 --> 00:19:11,110
narrator: underground, the tunneling team
337
00:19:11,110 --> 00:19:13,250
is still working as fast as they can.
338
00:19:13,250 --> 00:19:17,320
[ foreign ]
339
00:19:17,320 --> 00:19:22,860
each time the team breaks through into a station
340
00:19:22,860 --> 00:19:24,660
they face the same battle,
341
00:19:24,660 --> 00:19:28,330
to drag this 700-ton tunneling machine through the platform
342
00:19:28,330 --> 00:19:30,730
so they can continue digging.
343
00:19:30,730 --> 00:19:33,130
man: everybody wants to see the machine come in,
344
00:19:33,130 --> 00:19:35,670
but then a lot of people want to see it leave again
345
00:19:35,670 --> 00:19:38,200
because there's a lot of work that has to continue from there.
346
00:19:38,210 --> 00:19:40,870
there are deadlines to meet.
347
00:19:40,880 --> 00:19:42,940
narrator: the highly specialized tracklayers
348
00:19:42,940 --> 00:19:45,410
are hot on their heels.
349
00:19:45,410 --> 00:19:47,810
valerio and his team with the tunnel boring machine
350
00:19:47,820 --> 00:19:51,020
are furiously chomping through virgin dirt.
351
00:19:51,020 --> 00:19:54,220
our goal is to be as close as possible behind his team
352
00:19:54,220 --> 00:19:57,020
so that we can all finish this project on time.
353
00:19:57,020 --> 00:19:59,560
we have two tunnels, 17 stations.
354
00:19:59,560 --> 00:20:00,760
we've got a deadline.
355
00:20:00,760 --> 00:20:02,600
we need to achieve this fast.
356
00:20:05,170 --> 00:20:08,030
narrator: paul and his team need to position the track,
357
00:20:08,040 --> 00:20:11,970
secure it with concrete, and join each section together
358
00:20:11,970 --> 00:20:13,910
with absolute precision.
359
00:20:13,910 --> 00:20:15,780
it's no small feat.
360
00:20:20,850 --> 00:20:23,850
to help them install each piece in the right spot,
361
00:20:23,850 --> 00:20:26,920
they are using an innovative machine.
362
00:20:26,920 --> 00:20:29,060
this rail-laying gantry crane
363
00:20:29,060 --> 00:20:31,460
is fitted with precision-grabbing arms
364
00:20:31,460 --> 00:20:34,630
to pick up and position the flexible pieces of rail.
365
00:20:37,800 --> 00:20:39,870
man: there's a lot of skill involved in picking them up
366
00:20:39,870 --> 00:20:44,400
in the right position to minimize deflection.
367
00:20:44,410 --> 00:20:46,670
they do move around quite easily.
368
00:20:46,670 --> 00:20:49,740
they have to because the tunnel has so many twists and turns,
369
00:20:49,740 --> 00:20:51,480
it needs that flexibility.
370
00:20:54,420 --> 00:20:56,620
narrator: the flexible rail helps the track layers
371
00:20:56,620 --> 00:20:59,050
snake a path through the curved tunnels.
372
00:21:03,220 --> 00:21:05,290
burley: with curvature in one direction,
373
00:21:05,290 --> 00:21:07,430
we also come across the problem of one row
374
00:21:07,430 --> 00:21:09,700
getting longer or creeping ahead of the other.
375
00:21:09,700 --> 00:21:12,030
so every so often we need to perform a cut
376
00:21:12,030 --> 00:21:14,700
with a quick-cut saw to make sure that we're back on
377
00:21:14,700 --> 00:21:16,470
a level peg, and...
378
00:21:21,240 --> 00:21:23,510
narrator: they must level up the ends of the rail
379
00:21:23,510 --> 00:21:26,580
so that the next set of tracks joins up smoothly.
380
00:21:29,580 --> 00:21:34,050
any bumps or misalignments could derail a train.
381
00:21:34,060 --> 00:21:36,990
this is definitely, by far, the most important stage
382
00:21:36,990 --> 00:21:38,820
of the track-laying process.
383
00:21:42,530 --> 00:21:44,730
narrator: paul's team uses a plumb line
384
00:21:44,730 --> 00:21:47,200
to help them push or pull the rails into position
385
00:21:47,200 --> 00:21:50,800
with pinpoint accuracy.
386
00:21:50,800 --> 00:21:52,570
burley: without these sort of accuracies,
387
00:21:52,570 --> 00:21:54,810
there's a chance that the train could derail,
388
00:21:54,810 --> 00:21:56,680
and i'm my head's sort of moving around like this,
389
00:21:56,680 --> 00:21:58,280
i may as well catch a bus.
390
00:21:58,280 --> 00:22:01,210
it needs to be smooth.
391
00:22:01,220 --> 00:22:05,680
perfect.
392
00:22:05,690 --> 00:22:07,750
narrator: with the tracks perfectly in place,
393
00:22:07,760 --> 00:22:11,560
the team must now lock them into position with concrete.
394
00:22:11,560 --> 00:22:15,360
that's easier said than done.
395
00:22:15,360 --> 00:22:17,760
to secure the next 50 feet of track,
396
00:22:17,770 --> 00:22:21,230
they need to pump around 20 tons of wet concrete
397
00:22:21,240 --> 00:22:24,570
6 stories down to a mixer in the tunnels
398
00:22:24,570 --> 00:22:29,180
and feed it to the rail crew before it sets.
399
00:22:29,180 --> 00:22:32,580
it's a long distance in a short amount of time.
400
00:22:32,580 --> 00:22:35,580
burley: 90 minutes is the time that we have to ensure
401
00:22:35,580 --> 00:22:37,920
that the concrete is still in a condition
402
00:22:37,920 --> 00:22:39,920
that we can use to lock the sleepers
403
00:22:39,920 --> 00:22:42,590
into their final position.
404
00:22:42,590 --> 00:22:45,060
narrator: it takes over 40 minutes
405
00:22:45,060 --> 00:22:47,830
just to fill each mixer.
406
00:22:47,830 --> 00:22:49,660
burley: there's an enormous amount of pressure
407
00:22:49,660 --> 00:22:53,000
on these guys -- 90 minutes is not a long time.
408
00:22:53,000 --> 00:22:55,270
narrator: the load reaches the concreting crew
409
00:22:55,270 --> 00:22:57,340
with just minutes to spare.
410
00:22:57,340 --> 00:23:06,150
♪♪
411
00:23:06,150 --> 00:23:08,210
burley: time-wise, we're right on the limit.
412
00:23:08,220 --> 00:23:11,280
these guys have to work quick.
413
00:23:11,290 --> 00:23:13,150
time is critical.
414
00:23:13,150 --> 00:23:15,820
the men in white just performing the final concrete
415
00:23:15,820 --> 00:23:18,490
finishing work by hand.
416
00:23:18,490 --> 00:23:20,090
narrator: for this section of tunnel,
417
00:23:20,090 --> 00:23:22,500
they finished in time.
418
00:23:22,500 --> 00:23:25,430
burley: today, a good day if we get 80 meters done.
419
00:23:25,430 --> 00:23:28,030
only 31,500 meters to go.
420
00:23:28,040 --> 00:23:34,110
♪♪
421
00:23:34,110 --> 00:23:40,310
♪♪
422
00:23:40,310 --> 00:23:42,720
narrator: while work on both the tunneling
423
00:23:42,720 --> 00:23:44,320
and track laying picks up pace,
424
00:23:44,320 --> 00:23:46,790
1,200 miles away in italy,
425
00:23:46,790 --> 00:23:48,590
engineers are building the railway's
426
00:23:48,590 --> 00:23:52,660
39 new driverless trains.
427
00:23:52,660 --> 00:23:55,330
here, the team assembles each of the trains'
428
00:23:55,330 --> 00:23:59,200
three individual carriages,
429
00:23:59,200 --> 00:24:01,800
installs the doors and windows
430
00:24:01,800 --> 00:24:04,200
and connects up the complex electrical systems
431
00:24:04,210 --> 00:24:07,010
that will provide the driverless train controls.
432
00:24:09,810 --> 00:24:13,680
once built, each train is shipped to this test facility
433
00:24:13,680 --> 00:24:17,720
where davide marandola's team adds the finishing touches.
434
00:24:39,570 --> 00:24:41,640
♪♪
435
00:24:41,640 --> 00:24:44,180
narrator: hidden at the other end of the facility
436
00:24:44,180 --> 00:24:46,780
is cityringen's high speed test track
437
00:24:46,780 --> 00:24:51,920
where each driverless train must pass a series of critical tests.
438
00:24:51,920 --> 00:24:55,650
today, technicians plug into train 20's computer controls
439
00:24:55,660 --> 00:24:57,390
to track it's performance.
440
00:24:57,390 --> 00:25:01,060
♪♪
441
00:25:16,340 --> 00:25:19,950
narrator: davide will push this train to its limit.
442
00:25:19,950 --> 00:25:22,350
it must accelerate and break
443
00:25:22,350 --> 00:25:25,680
within a specified time and distance.
444
00:25:25,690 --> 00:25:28,020
marandola: it's crucial because we need to provide a train
445
00:25:28,020 --> 00:25:30,290
that is reliable.
446
00:25:30,290 --> 00:25:32,260
now we are going to the test track.
447
00:25:34,630 --> 00:25:36,430
narrator: if this train fails,
448
00:25:36,430 --> 00:25:39,630
it could delay work on the entire fleet.
449
00:25:53,580 --> 00:25:56,650
narrator: as part of copenhagen's ambitious
450
00:25:56,650 --> 00:25:58,450
$3.5 billion cityringen,
451
00:25:58,450 --> 00:26:03,260
engineers are testing a new fleet of driverless trains.
452
00:26:03,260 --> 00:26:04,790
but for this crucial test,
453
00:26:04,790 --> 00:26:07,790
a driver must sit in the hot seat.
454
00:26:07,800 --> 00:26:11,130
marandola: michael, can we get the four-signal ready?
455
00:26:11,130 --> 00:26:12,130
yeah.
456
00:26:12,130 --> 00:26:15,130
so the acceleration is quite strong.
457
00:26:15,140 --> 00:26:24,610
♪♪
458
00:26:24,610 --> 00:26:26,350
okay. now you can stop.
459
00:26:26,350 --> 00:26:32,620
♪♪
460
00:26:32,620 --> 00:26:35,620
narrator: now for the brake test.
461
00:26:35,620 --> 00:26:37,160
we are starting.
462
00:26:37,160 --> 00:26:41,660
then, when we reach max speed, we make max service brake.
463
00:26:41,660 --> 00:26:44,700
narrator: each train must be able to stop completely
464
00:26:44,700 --> 00:26:48,430
in less than 180 feet.
465
00:26:48,440 --> 00:26:50,370
marandola: okay. now you can stop.
466
00:26:50,370 --> 00:26:53,240
little, yeah.
467
00:26:53,240 --> 00:26:57,240
okay.
468
00:26:57,240 --> 00:26:58,710
yes.
469
00:26:58,710 --> 00:27:00,980
okay.
470
00:27:00,980 --> 00:27:02,780
narrator: after a day on the test tracks,
471
00:27:02,780 --> 00:27:05,520
it's the moment of truth.
472
00:27:05,520 --> 00:27:08,990
has this train passed both tests?
473
00:27:08,990 --> 00:27:11,460
marandola: we can evaluate increasing of the speed,
474
00:27:11,460 --> 00:27:14,790
so this yellow line, from zero to 40.
475
00:27:14,800 --> 00:27:17,800
that acceleration was 1.25,
476
00:27:17,800 --> 00:27:21,870
so it has been good -- reached in good way.
477
00:27:21,870 --> 00:27:24,070
narrator: the braking data shows that it stopped after
478
00:27:24,070 --> 00:27:27,810
just 160 feet, under the target.
479
00:27:30,880 --> 00:27:33,280
♪♪
480
00:27:33,280 --> 00:27:35,280
narrator: this train heads back to the base,
481
00:27:35,280 --> 00:27:38,080
having passed with flying colors.
482
00:27:38,090 --> 00:27:41,350
but with 19 more trains to put through this test,
483
00:27:41,360 --> 00:27:44,620
there's still a lot more work for davide's team to do.
484
00:27:44,620 --> 00:27:46,290
[ beeping ]
485
00:27:52,700 --> 00:27:56,440
narrator: as trains begin to line up ready to enter service,
486
00:27:56,440 --> 00:28:00,740
paul's track team is working 24/7 to install the rails.
487
00:28:03,710 --> 00:28:07,650
with a weld every 60 feet and over 19 miles of tunnel,
488
00:28:07,650 --> 00:28:09,450
it's a relentless battle.
489
00:28:11,850 --> 00:28:15,990
thousands and thousands of welds.
490
00:28:15,990 --> 00:28:18,320
narrator: paul and the team plan to use an ingenious
491
00:28:18,330 --> 00:28:20,530
and super fast welding technique
492
00:28:20,530 --> 00:28:22,560
to stop them from falling behind.
493
00:28:24,870 --> 00:28:27,670
they are preparing a fiery chemical reaction
494
00:28:27,670 --> 00:28:31,000
to super heat a mixture of aluminum and iron oxide
495
00:28:31,000 --> 00:28:33,340
that creates a mix of molten metal.
496
00:28:36,410 --> 00:28:38,740
this liquid metal should fill the gap
497
00:28:38,750 --> 00:28:41,280
between the rails in mere minutes.
498
00:28:41,280 --> 00:28:44,480
♪♪
499
00:28:44,490 --> 00:28:48,020
the advantage is the ability to join two unique bits of rail,
500
00:28:48,020 --> 00:28:51,560
creating one seamless stretch of railway line.
501
00:28:51,560 --> 00:28:54,030
now it's showtime.
502
00:28:54,030 --> 00:28:56,760
narrator: the chemical reaction is instantaneous.
503
00:28:56,760 --> 00:29:02,300
♪♪
504
00:29:02,300 --> 00:29:04,570
the liquid metal flows from the base of the drum
505
00:29:04,570 --> 00:29:07,510
into the mold.
506
00:29:07,510 --> 00:29:13,180
any excess drains into these pans on either side.
507
00:29:13,180 --> 00:29:15,310
burley: it's critical that we wait the right amount of time
508
00:29:15,320 --> 00:29:17,380
before removing the molds.
509
00:29:17,380 --> 00:29:19,920
if we remove the molds too early,
510
00:29:19,920 --> 00:29:22,650
the metal will run and fall out of the joint.
511
00:29:22,660 --> 00:29:26,330
if we remove it too late, we run the risk of having molten metal
512
00:29:26,330 --> 00:29:28,790
stuck to the track which is very hard to remove.
513
00:29:32,070 --> 00:29:34,800
narrator: once ready, they break the mold off
514
00:29:34,800 --> 00:29:37,870
and leave the weld to cool overnight.
515
00:29:37,870 --> 00:29:40,540
here we can see a thermite rail weld
516
00:29:40,540 --> 00:29:42,540
that was completed last night.
517
00:29:42,540 --> 00:29:46,210
we can see that the rail gap that we witnessed earlier
518
00:29:46,210 --> 00:29:50,880
is perfectly filled with the molten metal solution.
519
00:29:50,890 --> 00:29:53,420
it's had an initial grind,
520
00:29:53,420 --> 00:29:56,750
and it's ready for the final grinding later tomorrow.
521
00:29:56,760 --> 00:30:01,960
one rail weld completed, many thousands to go.
522
00:30:01,960 --> 00:30:05,300
narrator: the super fast welding helps paul's team
523
00:30:05,300 --> 00:30:08,170
join around 590 feet of track each night.
524
00:30:08,170 --> 00:30:11,300
♪♪
525
00:30:11,310 --> 00:30:15,370
across town, the team is gearing up to tunnel under
526
00:30:15,380 --> 00:30:19,510
copenhagen's historic central station.
527
00:30:19,510 --> 00:30:22,650
this iconic station was built in 1911,
528
00:30:22,650 --> 00:30:28,450
and now 100,000 commuters use this crucial hub every day.
529
00:30:28,460 --> 00:30:30,660
man: it's really important that we don't do any disruption
530
00:30:30,660 --> 00:30:32,120
to this because this is the main hub
531
00:30:32,130 --> 00:30:34,260
for central copenhagen, and all the trains heading out
532
00:30:34,260 --> 00:30:35,730
to other parts of denmark,
533
00:30:35,730 --> 00:30:38,200
so we cannot afford to cause any disruption
534
00:30:38,200 --> 00:30:40,070
to the station at all.
535
00:30:43,140 --> 00:30:45,740
narrator: for the ring of tunnels to reach
536
00:30:45,740 --> 00:30:48,610
their final station, engineers need to tunnel
537
00:30:48,610 --> 00:30:52,540
a mere 49 feet below this busy hub.
538
00:30:52,550 --> 00:30:55,080
no tunnels have come this close
539
00:30:55,080 --> 00:30:58,280
to copenhagen's oldest station before,
540
00:30:58,290 --> 00:30:59,820
and digging such huge holes
541
00:30:59,820 --> 00:31:02,820
so close to this historic brick-walled building,
542
00:31:02,820 --> 00:31:07,230
if not done right, could cause catastrophic damage
543
00:31:07,230 --> 00:31:10,160
and close this international hub for months.
544
00:31:12,230 --> 00:31:15,930
pulling this off without a hitch will be a huge challenge.
545
00:31:28,250 --> 00:31:31,320
narrator: in copenhagen, engineers are constructing
546
00:31:31,320 --> 00:31:33,390
the cityringen metro,
547
00:31:33,390 --> 00:31:34,920
but they're trying to figure out
548
00:31:34,920 --> 00:31:38,390
how to tunnel underneath the city's iconic central station
549
00:31:38,390 --> 00:31:41,590
without causing it to collapse.
550
00:31:41,600 --> 00:31:43,930
well, where we are at the moment is right next to copenhagen's
551
00:31:43,930 --> 00:31:45,200
main central station.
552
00:31:45,200 --> 00:31:46,930
just beyond that fence line
553
00:31:46,930 --> 00:31:49,530
is where the tbms will come through eventually,
554
00:31:49,540 --> 00:31:53,400
passing under the existing rail line.
555
00:31:53,410 --> 00:31:56,210
narrator: the team is so nervous about digging this section
556
00:31:56,210 --> 00:31:58,210
of tunnel that they have a special crew
557
00:31:58,210 --> 00:32:02,950
that monitors the operation 24/7.
558
00:32:02,950 --> 00:32:06,150
it rests on the shoulders of spyros latsenere
559
00:32:06,150 --> 00:32:09,390
to make sure the old station doesn't start collapsing.
560
00:32:33,050 --> 00:32:37,450
narrator: the plan is for workers to excavate the tunnels
561
00:32:37,450 --> 00:32:39,780
underneath the historic station.
562
00:32:39,790 --> 00:32:42,990
there's a real risk that the digging could disturb the earth
563
00:32:42,990 --> 00:32:47,190
around the tunnel boring machine causing the soil to shift
564
00:32:47,190 --> 00:32:50,400
and triggering the buildings above ground to tilt.
565
00:32:50,400 --> 00:32:53,130
to monitor for this, spyros and his team
566
00:32:53,130 --> 00:32:56,330
have installed an ingenious network of lasers and prisms
567
00:32:56,340 --> 00:33:00,070
all over the station to check for any ground movement.
568
00:33:00,070 --> 00:33:02,670
the laser fires a beam every 30 minutes
569
00:33:02,680 --> 00:33:06,340
to record the position of the prisms.
570
00:33:06,350 --> 00:33:09,820
if the spot the laser beam hits suddenly changes,
571
00:33:09,820 --> 00:33:12,220
this means that the prism has moved,
572
00:33:12,220 --> 00:33:14,990
and the system sends an alert back to the base.
573
00:33:27,770 --> 00:33:30,500
narrator: inch by inch, the tunnel boring machine
574
00:33:30,500 --> 00:33:33,640
slowly snakes its way under the main station.
575
00:33:35,110 --> 00:33:39,040
[ foreign ]
576
00:33:39,050 --> 00:33:41,980
narrator: it's a tense time for the tunneling crew,
577
00:33:41,980 --> 00:33:44,180
as they approach the point where they will make the final
578
00:33:44,180 --> 00:33:47,520
breakthrough next to the main station.
579
00:33:47,520 --> 00:33:49,290
okay, guys. welcome.
580
00:33:49,290 --> 00:33:54,130
it's the moment they've all been working towards.
581
00:33:54,130 --> 00:33:55,590
man: the main focus point today
582
00:33:55,600 --> 00:33:57,860
is going to be the final breakthrough.
583
00:33:57,870 --> 00:33:59,660
so of course it's not just a final breakthrough.
584
00:33:59,670 --> 00:34:02,330
it's the last breakthrough of the entire project.
585
00:34:02,340 --> 00:34:05,000
we've been part of this project now for the last three years,
586
00:34:05,000 --> 00:34:07,070
and it all comes to this point when it breaks through.
587
00:34:07,070 --> 00:34:09,340
we need to keep our focus on the safe distance
588
00:34:09,340 --> 00:34:10,410
for the spectators,
589
00:34:10,410 --> 00:34:11,740
and especially with this breakthrough,
590
00:34:11,750 --> 00:34:12,740
there's going to be a lot of people
591
00:34:12,750 --> 00:34:13,750
that want to get in there.
592
00:34:13,750 --> 00:34:15,210
there will be a lot of eyes on us,
593
00:34:15,220 --> 00:34:17,420
and in that respect, we want to make sure that we do this
594
00:34:17,420 --> 00:34:18,820
and it's a nice clean breakthrough
595
00:34:18,820 --> 00:34:20,690
and without incident. okay. thank you.
596
00:34:20,690 --> 00:34:23,620
okay. thank you, sir.
597
00:34:23,620 --> 00:34:25,690
narrator: but just as the tunnelers reach
598
00:34:25,690 --> 00:34:27,690
the halfway point under the station,
599
00:34:27,690 --> 00:34:31,360
some alarming readings alert spyros' team to a problem.
600
00:34:52,050 --> 00:34:54,650
narrator: the alert couldn't have come
601
00:34:54,650 --> 00:34:56,520
at a more inconvenient time.
602
00:34:56,520 --> 00:35:00,130
spyros sends a team of surveyors to investigate
603
00:35:00,130 --> 00:35:01,460
if the settling earth
604
00:35:01,460 --> 00:35:04,400
is calling the platform's roof pillars to sink.
605
00:35:04,400 --> 00:35:13,870
♪♪
606
00:35:13,870 --> 00:35:18,540
we had some points moving, and we're double checking to see
607
00:35:18,550 --> 00:35:20,080
if they continue to move
608
00:35:20,080 --> 00:35:22,880
or if they are staying in the same level
609
00:35:22,880 --> 00:35:24,480
because the tunnel boring machine
610
00:35:24,480 --> 00:35:26,620
is right underneath us here,
611
00:35:26,620 --> 00:35:29,420
so we'll double check if it's all right.
612
00:35:29,420 --> 00:35:31,020
a lot of things could happen here.
613
00:35:31,020 --> 00:35:33,560
there's a very big arch over us,
614
00:35:33,560 --> 00:35:36,360
so if something happens with some of the pillars here,
615
00:35:36,360 --> 00:35:38,760
if part of the tunnel starts collapsing
616
00:35:38,770 --> 00:35:40,300
or something like this,
617
00:35:40,300 --> 00:35:45,040
we will know it before it gets critical.
618
00:35:45,040 --> 00:35:48,110
narrator: they check all 60 prisms in the station,
619
00:35:48,110 --> 00:35:51,580
dodging commuters who are oblivious to the massive machine
620
00:35:51,580 --> 00:35:53,750
passing right beneath their feet.
621
00:35:56,450 --> 00:35:59,320
some days i can actually feel the boring machine
622
00:35:59,320 --> 00:36:03,650
moving under my feet, like, vibrating the ground.
623
00:36:03,660 --> 00:36:08,390
♪♪
624
00:36:08,400 --> 00:36:12,460
i will transfer the calculations from today.
625
00:36:12,470 --> 00:36:14,870
we can then see what was measured,
626
00:36:14,870 --> 00:36:18,540
and the two points that we measured
627
00:36:18,540 --> 00:36:22,140
that was close to the alarm levels
628
00:36:22,140 --> 00:36:25,880
are about the same height that they were last time.
629
00:36:25,880 --> 00:36:28,080
so they stopped moving down.
630
00:36:28,080 --> 00:36:30,020
everything is stable,
631
00:36:30,020 --> 00:36:33,820
and everything is where it's supposed to be.
632
00:36:33,820 --> 00:36:37,290
narrator: the data confirms that the ground has stopped moving,
633
00:36:37,290 --> 00:36:39,760
at least for now.
634
00:36:39,760 --> 00:36:43,900
♪♪
635
00:36:43,900 --> 00:36:46,700
so the tunnelers are clear to press on with the last
636
00:36:46,700 --> 00:36:49,100
push towards the finishing line,
637
00:36:49,100 --> 00:36:54,170
and the final breakthrough into the new cityringen station.
638
00:36:54,170 --> 00:36:56,310
man: i think we should have them at this point here
639
00:36:56,310 --> 00:36:58,180
rather than the bottom level.
640
00:36:58,180 --> 00:37:00,510
in my opinion, it's a bit too close.
641
00:37:00,510 --> 00:37:03,450
so we have that little bit more extra space.
642
00:37:03,450 --> 00:37:05,450
narrator: hundreds of vips and officials
643
00:37:05,450 --> 00:37:09,590
are due to arrive to witness this momentous event.
644
00:37:09,590 --> 00:37:12,520
paul can't afford anything to go wrong.
645
00:37:12,530 --> 00:37:14,190
so tomorrow everything is going to be nice and clean
646
00:37:14,190 --> 00:37:16,130
and ready for the final breakthrough.
647
00:37:16,130 --> 00:37:19,260
okay. i have no problems.
648
00:37:19,270 --> 00:37:21,870
narrator: the team has enlisted some extra special help
649
00:37:21,870 --> 00:37:24,270
to make sure the final breakthrough goes off
650
00:37:24,270 --> 00:37:25,770
without a hitch.
651
00:37:28,740 --> 00:37:30,740
evans: that's a statue of the santa barbara.
652
00:37:30,740 --> 00:37:32,540
she's the patron saint of miners.
653
00:37:32,550 --> 00:37:36,750
so wherever we go, we would like to have the statue there
654
00:37:36,750 --> 00:37:38,750
as a good luck symbol for our mining,
655
00:37:38,750 --> 00:37:41,690
to keep us safe wherever we may be underground.
656
00:37:41,690 --> 00:37:43,220
she's brought us luck all this way,
657
00:37:43,220 --> 00:37:45,890
so why shouldn't she bring us luck for the final breakthrough?
658
00:37:45,890 --> 00:37:49,430
♪♪
659
00:37:49,430 --> 00:37:52,030
narrator: after three years of construction work,
660
00:37:52,030 --> 00:37:57,570
the day of the final tunneling breakthrough finally arrives.
661
00:37:57,570 --> 00:38:02,440
everything has been leading up to this crucial event.
662
00:38:02,440 --> 00:38:05,980
the final act, today is the end,
663
00:38:05,980 --> 00:38:09,250
at least of the tunneling operation.
664
00:38:09,250 --> 00:38:10,850
evans: we're all ready. we're all set up, ready to go.
665
00:38:10,850 --> 00:38:12,580
we're just waiting for the last of the visitors
666
00:38:12,590 --> 00:38:13,850
and guests to arrive,
667
00:38:13,850 --> 00:38:15,920
and then we'll get the all clear,
668
00:38:15,920 --> 00:38:18,420
and we'll be ready to push.
669
00:38:31,340 --> 00:38:34,810
narrator: in copenhagen, engineers are coming upon
670
00:38:34,810 --> 00:38:39,880
the final stages of completing the $3.5 billion cityringen.
671
00:38:39,880 --> 00:38:42,810
the last major milestone is breaking down the walls
672
00:38:42,820 --> 00:38:45,680
beneath the city's historic central station.
673
00:38:48,820 --> 00:38:51,960
with a subterranean feast complete with champagne
674
00:38:51,960 --> 00:38:54,690
and red carpet all laid out,
675
00:38:54,690 --> 00:38:57,230
the pressure grows on the tunneling team.
676
00:38:57,230 --> 00:38:58,500
there's a big buzz in the air,
677
00:38:58,500 --> 00:39:00,300
and everyone is excited to see this happen.
678
00:39:00,300 --> 00:39:04,170
welcome to the last break in of the project.
679
00:39:04,170 --> 00:39:07,570
we're going to go through a couple of safety issues.
680
00:39:07,570 --> 00:39:09,640
narrator: inside the tunneling machine,
681
00:39:09,640 --> 00:39:12,680
sybil yensen gears up for the final push.
682
00:39:14,780 --> 00:39:16,310
sybil, sybil, this is paul.
683
00:39:16,320 --> 00:39:17,980
radio check, over.
684
00:39:17,980 --> 00:39:19,650
hey, paul. this is sybil and tbm-4.
685
00:39:19,650 --> 00:39:21,720
we can hear you loud and clear.
686
00:39:21,720 --> 00:39:24,190
okay, good. everything looking good your side?
687
00:39:24,190 --> 00:39:26,520
yes. we checked the pumps. everything is ready.
688
00:39:26,530 --> 00:39:28,990
thank you so much.
689
00:39:32,130 --> 00:39:33,330
everything is good to go on their side.
690
00:39:33,330 --> 00:39:35,470
everything is how it should be.
691
00:39:35,470 --> 00:39:36,800
let's go.
692
00:39:36,800 --> 00:39:38,800
starting to roll now.
693
00:39:38,810 --> 00:39:40,400
okay. we can start pushing now.
694
00:39:40,410 --> 00:39:41,940
we'll start.
695
00:39:41,940 --> 00:39:44,610
[ foreign ]
696
00:39:44,610 --> 00:39:53,620
♪♪
697
00:39:53,620 --> 00:40:02,690
♪♪
698
00:40:02,700 --> 00:40:05,160
narrator: with one final nudge...
699
00:40:07,770 --> 00:40:11,500
19 miles of cityringen tunnels are complete,
700
00:40:11,510 --> 00:40:14,840
and the 17 new stations finally connect.
701
00:40:19,110 --> 00:40:23,180
woo!
702
00:40:23,180 --> 00:40:25,780
narrator: for valerio, paul, and the whole team,
703
00:40:25,790 --> 00:40:30,620
it's the end of an extraordinary underground journey.
704
00:40:33,130 --> 00:40:36,530
brilliant, fantastic, extremely happy.
705
00:40:36,530 --> 00:40:38,930
for copenhagen, it means that you can walk from here
706
00:40:38,930 --> 00:40:39,930
all around town
707
00:40:39,930 --> 00:40:42,200
and come back from that direction.
708
00:40:42,200 --> 00:40:44,000
it's the first big,
709
00:40:44,000 --> 00:40:47,670
huge step towards the completion of the metro.
710
00:40:47,670 --> 00:40:49,940
it's been a massive achievement for everybody involved.
711
00:40:49,940 --> 00:40:51,810
everybody is so happy.
712
00:40:51,810 --> 00:40:53,610
now today is just celebration.
713
00:40:53,610 --> 00:40:55,780
they are just celebrating what they did.
714
00:40:58,550 --> 00:41:00,950
narrator: but just one final breakthrough remains
715
00:41:00,950 --> 00:41:03,190
to mark this huge achievement.
716
00:41:05,230 --> 00:41:08,690
woo-hoo!
717
00:41:08,700 --> 00:41:10,360
[ foreign ]
718
00:41:10,360 --> 00:41:11,900
have you seen this cake?
719
00:41:11,900 --> 00:41:15,900
[ cheering ]
720
00:41:15,900 --> 00:41:21,440
♪♪
721
00:41:21,440 --> 00:41:23,510
narrator: the last tunneling breakthrough
722
00:41:23,510 --> 00:41:25,510
marks a key milestone in this ambitious
723
00:41:25,510 --> 00:41:29,050
$3.5 billion project.
724
00:41:29,050 --> 00:41:33,590
all the major civil engineering work is now complete.
725
00:41:33,590 --> 00:41:37,060
the team has poured more than one million tons of concrete...
726
00:41:39,530 --> 00:41:43,790
excavated more than 3 million tons of earth,
727
00:41:43,800 --> 00:41:48,270
and installed 135,000 tunnel segments.
728
00:41:48,270 --> 00:41:52,340
we've done our job, and we've done it very well.
729
00:41:52,340 --> 00:41:53,610
man: it's huge. it's very big.
730
00:41:53,610 --> 00:41:57,680
i really need to take time to process it.
731
00:41:57,680 --> 00:41:59,410
narrator: over the coming months,
732
00:41:59,410 --> 00:42:00,750
the copenhagen metro team
733
00:42:00,750 --> 00:42:03,880
will continue to lay the last sections of track,
734
00:42:03,880 --> 00:42:07,820
install the stations so the ticket halls can open
735
00:42:07,820 --> 00:42:11,560
and prepare the 39 trains for operation.
736
00:42:11,560 --> 00:42:13,160
man: when this is all finished, i want to come back
737
00:42:13,160 --> 00:42:15,590
and take the first ride on the metro.
738
00:42:15,600 --> 00:42:17,960
i'm definitely going to do that.
739
00:42:17,960 --> 00:42:20,770
narrator: cityringen will soon ease the pressure
740
00:42:20,770 --> 00:42:22,030
on copenhagen's roads
741
00:42:22,040 --> 00:42:25,100
and help keep this historic capital city
742
00:42:25,100 --> 00:42:27,940
running well into the next century.
57184
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