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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
With a black market for firearms
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00:00:55,827 --> 00:00:57,793
And terrorism
A worldwide threat,
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00:00:57,793 --> 00:01:00,275
Armed forces need to protect
Their munitions
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00:01:00,275 --> 00:01:02,413
From getting
Into the wrong hands.
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00:01:02,413 --> 00:01:05,965
Weapons are often stored in
Earth-covered concrete bunkers
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00:01:05,965 --> 00:01:08,000
That have special doors.
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These mammoth steel doors
Are designed to prevent anyone
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From blasting their way
Into a military bunker
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To access the munitions
Stored inside.
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The key to the doors'
Exceptional strength --
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00:01:28,172 --> 00:01:30,620
A grid structure core
Made from steel slats
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6 inches wide and 6mm thick.
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A computer-guided torch
Notches half the slats
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So the other half
Can slot into them
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To form the grid structure.
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00:01:49,482 --> 00:01:51,448
Workers assemble
The grid structure
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On top of a nearly
1/2-inch-thick steel plate,
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The exterior face of the door.
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Because the grids have
Empty space in the middle,
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They provide
Three-dimensional strength
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Without the excessive weight
Of a solid core.
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00:02:04,517 --> 00:02:08,862
Even so, these doors
Weigh almost 10 tons each.
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00:02:10,689 --> 00:02:12,655
Once the slats
Are all assembled,
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00:02:12,655 --> 00:02:16,379
Workers weld the bottom
Of the grids to the plate.
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00:02:18,172 --> 00:02:22,517
Then with a manual gas torch,
They trim the ends of the slats
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So they'll fit inside
The channel of the steel framing
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00:02:25,586 --> 00:02:27,724
That will run
Around the perimeter.
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Once they've installed framing
On all four sides,
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They clamp everything
In position,
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Then weld all around.
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They run a string line
To properly position
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00:03:00,068 --> 00:03:02,068
And weld l-shaped steel tabs
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00:03:02,068 --> 00:03:04,517
To the top
Of the grid structure.
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00:03:06,000 --> 00:03:08,034
These tabs, two per grid,
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Will support the interior face
Of the door.
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00:03:18,896 --> 00:03:22,655
Then they fill each grid
With mineral fiber insulation.
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This prevents moisture
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00:03:24,275 --> 00:03:27,103
From condensing
On the inside of the door.
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00:03:40,034 --> 00:03:43,068
They take the steel plate
For the interior door face,
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Drill several 1/2-inch-wide
Holes through it...
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...And lay it
Onto the structure,
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Aligning the holes
With the grid tabs.
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Then they weld the plate's
Perimeter to the framing
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00:03:58,620 --> 00:04:01,310
And each hole
To the grid tab beneath it.
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00:04:16,241 --> 00:04:19,724
Once workers have finished
Constructing the doors,
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They weld on hinge pins
And locking mechanisms.
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00:04:23,000 --> 00:04:25,103
The frame
On which the doors hang
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00:04:25,103 --> 00:04:27,620
Is made of two heavy,
Vertical steel beams
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With hinge pin receivers
And two horizontal steel tubes.
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In the middle
Is a temporary cross bracing
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To keep the frame square
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And to prevent it from buckling
Under the weight of the doors
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Before installation is complete.
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00:04:44,172 --> 00:04:49,206
Onsite, the installers
First mount the door frame.
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00:04:49,206 --> 00:04:52,206
Then, using a forklift
With an extended boom,
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00:04:52,206 --> 00:04:54,068
A type of heavy lifting arm,
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They carefully descend
The door's hinge pins
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Into the receivers on the frame.
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Crews then build
The bunker's concrete structure
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Around the installed door.
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Once the concrete
Has properly cured,
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They remove the frame
Cross bracing.
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A handle on the door
Releases a foot bolt,
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Which slots into the base
Of the frame.
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This prevents the locked door
From bowing.
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00:05:26,137 --> 00:05:28,758
The lock itself
Is a massive dead bolt
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00:05:28,758 --> 00:05:31,724
With a tungsten-carbide rod
Inside,
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Making it impossible
To saw through.
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As an added layer of security,
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The military installs
A monitoring system
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That sends out a signal
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The second anyone tries
To open the door,
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Even with the key.
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If the entry is unauthorized,
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Soldiers descend on the bunker
To apprehend the intruder.
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Narrator: throughout history,
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Women have enhanced their lips
With color.
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Cleopatra led the way
Over 2,000 years ago.
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She used crushed ants
And beetles to redden her lips.
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Today a tube of lipstick
Does the job nicely.
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No need to mess around
With crushed bugs.
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Lipstick comes in a case
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That also serves
As an applicator,
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And that's the beauty of it.
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Just just twist the stick
And apply color
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To make lackluster lips
Look luscious.
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Lipstick ingredients
Include waxes,
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Pigments, and moisturizers.
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A worker pre-weighs everything
Following a formula.
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The exact blends
Are usually a company secret.
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She pours the measured
Ingredients into a kettle,
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That melts
And mixes them together.
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She adds a plant-based gel
Known as plantolatum.
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It will act as a skin softener
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And also enable the lipstick
To be smoothly applied.
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Different waxes -- carnauba,
Candelilla, and beeswax --
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Add body to the mixture.
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The waxes will also
Give the lipstick
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A certain sheen
Upon application.
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With the base mixture prepared,
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She now whips up
A batch of pigment
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Using different
Iron oxide colorants.
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She scoops it onto rollers
That grind the pigment particles
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While rolling it
Into sheet form.
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It takes three passes
Through the rollers
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To fully grind the pigment.
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It's ready to be added
To the base mixture.
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She lowers the heat
In the kettle
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To avoid
Scalding the ingredients.
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She adds pigment
Until the mixture thickens
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And becomes creamy.
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It's now the right consistency
To be shaped into lipstick.
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It's over to the next station
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Where another worker
Pours the lipstick liquid
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Into a filling machine.
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This filling system
Also has a mixer
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That keeps the consistency
Creamy.
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She places a mold
Under the filling machine
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00:08:23,586 --> 00:08:25,000
And activates a lift.
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It serves up the mold to nozzles
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That pump lipstick liquid
Into the slots of the mold.
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00:08:31,206 --> 00:08:33,793
She continues to fill
Lipstick molds
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Until the supply in the machine
Has been depleted.
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She places the molds
On a conveyer,
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Which takes them
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Through a nearly five-foot-long
Cooling tunnel.
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00:08:44,103 --> 00:08:47,724
The chilly trip causes
The lipstick liquid to solidify.
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The lipsticks are now ready
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For their swiveling,
Tubular containers.
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She places a rack
On top of the mold
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And inserts the cases
Into slots on the rack.
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00:09:02,551 --> 00:09:07,965
The slots are aligned
With the lipsticks in the mold.
135
00:09:07,965 --> 00:09:12,275
Then it's over
To the turnaround machine.
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00:09:12,275 --> 00:09:14,896
Bursts of air
Gently push the lipstick
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00:09:14,896 --> 00:09:17,896
Out of the mold
And up into the cases.
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00:09:17,896 --> 00:09:20,965
To assist,
Little pushers apply pressure
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00:09:20,965 --> 00:09:23,103
To the bottoms of the cases.
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00:09:23,103 --> 00:09:26,379
The lipsticks have made
Their transfer without a smudge.
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00:09:26,379 --> 00:09:32,275
She sets them down
And removes the transfer rack.
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00:09:32,275 --> 00:09:36,344
On another conveyor,
The lipsticks pass by heat guns.
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The hot air melts the lipsticks
Just a little
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To make them shine.
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00:09:40,965 --> 00:09:44,344
Continuing on, the lipsticks
Travel past rollers
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00:09:44,344 --> 00:09:50,034
That turn the cases to cause
The lipsticks to swivel down.
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00:09:50,034 --> 00:09:53,344
A testers samples a lipstick
From every batch
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00:09:53,344 --> 00:09:55,517
To determine the melting point.
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This is important
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00:09:56,689 --> 00:09:58,551
Because lipstick should be
Stable enough
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00:09:58,551 --> 00:10:02,965
Not to melt in a purse
On a hot day.
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00:10:02,965 --> 00:10:06,551
He smears lipstick shavings
Onto a glass disk
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00:10:06,551 --> 00:10:10,724
And examines their consistency.
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00:10:10,724 --> 00:10:15,103
He places the sample
On a heating element
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00:10:15,103 --> 00:10:18,896
And swings a magnifying glass
Overhead for a close-up view
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00:10:18,896 --> 00:10:21,931
As the lipstick shavings
Melt into a puddle.
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00:10:24,000 --> 00:10:25,620
Checking a thermometer,
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00:10:25,620 --> 00:10:28,034
He confirms
That the melting point
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Is within an acceptable range.
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00:10:32,137 --> 00:10:34,344
Another worker
Then compares the color
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Of the freshly made lipstick
To the standard,
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And it's a match.
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So they wrap up production
With a plastic cap.
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The cap is clear to showcase
The shade of the lipstick.
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00:10:50,965 --> 00:10:54,931
It has taken about a day
To manufacture this lipstick.
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00:10:54,931 --> 00:10:57,551
It's time to freshen up.
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Narrator: there's no need
To close your eyes
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00:11:11,241 --> 00:11:13,586
And imagine you're in
A tropical paradise
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00:11:13,586 --> 00:11:17,241
When artificial palm trees
Are part of the landscaping.
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00:11:17,241 --> 00:11:20,724
They can provide a touch
Of tropical in any climate,
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00:11:20,724 --> 00:11:22,413
But making a synthetic copy
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00:11:22,413 --> 00:11:25,034
Of one of nature's
Towering achievements
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00:11:25,034 --> 00:11:27,275
Is no small task.
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00:11:30,758 --> 00:11:32,620
With artificial palm trees,
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00:11:32,620 --> 00:11:36,068
There are no watering
Or other maintenance worries,
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So you really have it made
In the shade.
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00:11:40,344 --> 00:11:44,896
To manufacture a palm tree,
A worker wraps sticky mesh tape
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Around a tubular piece
Of polyvinyl chloride.
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00:11:48,551 --> 00:11:51,413
This tube will establish
The shape of the trunk,
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00:11:51,413 --> 00:11:54,655
And the tape will allow
The next layers to adhere to it.
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00:11:56,862 --> 00:11:59,379
While all that taping
Is going on,
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A welder pieces together
The tree's solid-steel skeleton.
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He welds the base plate
To a pole.
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00:12:07,413 --> 00:12:12,931
He strengthens the joint with
Lateral supports called gussets.
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00:12:12,931 --> 00:12:15,586
The gussets
Should enable the palm tree
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00:12:15,586 --> 00:12:17,206
To withstand heavy winds.
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00:12:19,896 --> 00:12:22,172
He adds height
To the tree skeleton
188
00:12:22,172 --> 00:12:23,931
With another piece of steel.
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00:12:23,931 --> 00:12:28,034
Artificial palm trees can be
Made to exact specifications,
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00:12:28,034 --> 00:12:31,103
While in nature,
Things are less precise.
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00:12:33,724 --> 00:12:36,275
After a coat
Of rust-inhibiting paint,
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00:12:36,275 --> 00:12:39,034
They're ready to insert
The steel skeleton
193
00:12:39,034 --> 00:12:42,172
Into the taped pvc pipe.
194
00:12:42,172 --> 00:12:44,379
One worker clamps
The end of the steel structure
195
00:12:44,379 --> 00:12:45,827
To a table,
196
00:12:45,827 --> 00:12:48,965
And the other member of the team
Slides the trunk core onto it.
197
00:12:51,689 --> 00:12:54,241
They screw the trunk
To the steel skeleton
198
00:12:54,241 --> 00:12:56,586
In several places.
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00:12:56,586 --> 00:12:59,310
With a foot pedal,
200
00:12:59,310 --> 00:13:01,896
A member of the team
Activates a spindle,
201
00:13:01,896 --> 00:13:03,793
And it turns the palm tree trunk
202
00:13:03,793 --> 00:13:07,586
So he can efficiently wrap
Synthetic rubber around it.
203
00:13:07,586 --> 00:13:12,000
The effect simulates
Natural growth rings.
204
00:13:12,000 --> 00:13:15,413
He brushes an adhesive
Onto the rubber,
205
00:13:15,413 --> 00:13:17,413
Ensuring complete coverage.
206
00:13:21,448 --> 00:13:25,793
The adhesive is high-strength
And waterproof,
207
00:13:25,793 --> 00:13:28,586
Qualities that will allow
This synthetic concrete
208
00:13:28,586 --> 00:13:30,931
To stick to it
In all kinds of weather.
209
00:13:30,931 --> 00:13:33,827
The concrete is made
Of many components,
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00:13:33,827 --> 00:13:36,551
Including silicone
And liquid rubber,
211
00:13:36,551 --> 00:13:39,931
And is the consistency
Of peanut butter.
212
00:13:39,931 --> 00:13:44,137
He spreads it
Onto the entire palm tree trunk.
213
00:13:44,137 --> 00:13:47,379
After an overnight cure,
The coating solidifies
214
00:13:47,379 --> 00:13:50,379
And he paints it
With exterior latex paint
215
00:13:50,379 --> 00:13:52,517
Using a light touch.
216
00:13:52,517 --> 00:13:54,724
He adds contrast
With darker paint.
217
00:13:54,724 --> 00:13:57,793
It highlights the rubber ridges
On the trunk
218
00:13:57,793 --> 00:13:59,827
To make it look more authentic.
219
00:14:02,517 --> 00:14:04,103
While the paint dries,
220
00:14:04,103 --> 00:14:07,758
He turns his attention
To the slotted steel trunk cap.
221
00:14:09,655 --> 00:14:14,724
He applies some of the synthetic
Concrete used on the trunk.
222
00:14:14,724 --> 00:14:16,724
It will serve as an adhesive
223
00:14:16,724 --> 00:14:20,344
As he now presses
A cocoa-fiber fringe to the cap.
224
00:14:22,931 --> 00:14:26,103
The fringe of fiber
Camouflages the steel
225
00:14:26,103 --> 00:14:29,655
And makes the cap
Look like a tree husk.
226
00:14:29,655 --> 00:14:33,620
He ties it with wire
To maintain the arrangement.
227
00:14:38,448 --> 00:14:43,413
He tightens it with pliers
And snips off the excess.
228
00:14:43,413 --> 00:14:47,965
He disguises the wire with more
Of the synthetic concrete.
229
00:14:50,931 --> 00:14:55,344
And after it cures, he paints it
To match the cocoa fibers.
230
00:14:57,517 --> 00:15:01,448
Successfully disguised
By cocoa fiber and paint,
231
00:15:01,448 --> 00:15:04,206
He bolts the steel cap
To the treetop.
232
00:15:07,379 --> 00:15:10,379
The next worker
Tapes a flat steel bar
233
00:15:10,379 --> 00:15:14,551
To the stem of palm foliage
Which is made of polyethylene.
234
00:15:19,931 --> 00:15:23,827
He reinforces the job
With two metal clamps.
235
00:15:27,310 --> 00:15:33,137
He crimps the clamps tightly
To the stem and bar.
236
00:15:35,931 --> 00:15:38,586
These palm fronds,
As they're called,
237
00:15:38,586 --> 00:15:40,448
Provide the crowning touch.
238
00:15:40,448 --> 00:15:43,275
They insert the steel bars
In the slotted cap
239
00:15:43,275 --> 00:15:47,275
And then bend the fronds back
To a more realistic angle.
240
00:15:52,034 --> 00:15:53,931
It's taken
About an hour and a half
241
00:15:53,931 --> 00:15:57,068
To manufacture
This artificial palm tree,
242
00:15:57,068 --> 00:16:00,793
Easier than waiting a decade
Or more for a real one to grow.
243
00:16:00,793 --> 00:16:05,344
And with the job done,
It's time for a piƱa colada.
244
00:16:17,448 --> 00:16:18,586
Narrator: a brass plaque
245
00:16:18,586 --> 00:16:20,689
Prominently identifies
An important site.
246
00:16:20,689 --> 00:16:23,620
Think historical landmarks,
Memorials,
247
00:16:23,620 --> 00:16:26,689
Hospital donor walls,
Walks of fame.
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Many professional firms
Identify their offices
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And many homes
Display their addresses
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With an elegant plaque
Made of brass.
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A brass plaque makes a bold
And lasting statement.
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Making one
Begins with a wooden model,
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Minus the lettering,
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Covered in artificial leather
Where they want a bumpy texture.
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They use this model
To cast an aluminum pattern.
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A typesetter draws guidelines
On the pattern
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For the inscription,
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Then glues pewter lettering
On the lines.
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Getting the pattern perfect
Is essential,
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As this is what they use
To make the sand mold
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For casting the brass plaque.
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The typesetter hands off
The pattern to the molders,
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Who spray the surface
With a release agent,
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The industrial version
Of nonstick cooking spray.
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This will prevent the pattern
From adhering
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00:17:21,206 --> 00:17:24,241
To the sand mold
They're about to make with it.
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00:17:24,241 --> 00:17:27,551
After laying the pattern
In a high-edge steel frame,
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They pour in a mixture
Of silica sand and resin,
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Filling it to the top
And compacting tightly.
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00:17:34,758 --> 00:17:38,275
After 15 minutes,
The resin cures,
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Binding the grains of sand.
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00:17:40,137 --> 00:17:44,275
The molders then flip the frame
And lift off the top half of it.
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A hard block of sand
Is in the bottom half
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Containing a mirror image
Of the plaque pattern.
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This is the sand mold
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With which they'll cast
The plaque in brass.
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The molders
Now spray the surface
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With a solution
Of alcohol and graphite,
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Then they burn off the alcohol
With a lighter,
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00:18:04,000 --> 00:18:06,379
Leaving behind
A film of graphite.
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00:18:06,379 --> 00:18:08,034
This heat-resistant layer
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Will prevent the sand mold
From eroding
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00:18:10,655 --> 00:18:13,827
When it comes into contact
With the molten metal.
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00:18:13,827 --> 00:18:18,172
Workers charge the furnace
With brass ingots,
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As well as with pieces of excess
Brass from previous castings.
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00:18:22,482 --> 00:18:25,827
The furnace temperature,
2,300 degrees fahrenheit,
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Liquifies the solid metal
In about 20 minutes.
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00:18:29,137 --> 00:18:31,551
Then the molders
Pour the molten brass
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00:18:31,551 --> 00:18:33,965
Through a hole
At the top of the mold.
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00:18:33,965 --> 00:18:37,793
The hole feeds two channels
Leading to the cavity.
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The metal
Begins solidifying immediately.
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00:18:42,448 --> 00:18:44,034
However, it's a good hour
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Before the casting
Is fully hardened,
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At which point, they open
The mold to extract the plaque.
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00:18:51,206 --> 00:18:53,344
Attached to it are runners,
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Excess metal that solidifies
In the channels
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Leading to the mold cavity.
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00:18:59,172 --> 00:19:02,137
So, after knocking the sand
Out of the frame
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00:19:02,137 --> 00:19:03,689
To release the plaque...
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00:19:08,413 --> 00:19:10,241
...They saw off the runners,
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Then throw them
Back into the furnace
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To be remelted
For the next casting.
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They grind the edge
Of the plaque
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00:19:17,620 --> 00:19:19,172
With an abrasive wheel,
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00:19:19,172 --> 00:19:22,103
Smoothing the nubs
Where the runners were cut off
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And making the plaque perfectly
Round and straight-edged.
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With a steel scraper,
They clean up the surface,
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Removing flakes of metal
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And remnants of sand
And graphite.
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00:19:35,689 --> 00:19:39,931
They dissolve sulfurated potash
In warm water.
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This chemical solution
Oxidizes metal,
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Creating what looks like
A natural patina,
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A darkening of the surface
That develops with age.
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00:19:59,931 --> 00:20:02,068
After preparing the solution,
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00:20:02,068 --> 00:20:04,827
They transfer it
To a large basin.
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00:20:04,827 --> 00:20:07,448
A kiddy wading pool
Does the trick.
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Then they dip the plaque,
Keeping it submerged
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00:20:12,758 --> 00:20:16,724
Until they get enough patina
To make the brass look antique.
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00:20:20,275 --> 00:20:23,034
They rinse off the chemical
With water
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00:20:23,034 --> 00:20:25,793
And dry the plaque
With compressed air.
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00:20:30,275 --> 00:20:33,068
They gently press
A vibrating abrasive belt
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Against the plaque.
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00:20:35,275 --> 00:20:38,758
It polishes the raised surfaces,
Removing their patina
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And restoring
Their brassy shine.
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This finishing creates depth
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By highlighting the relief
Against the dark background.
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00:20:56,206 --> 00:20:59,034
Just one last step
Before the plaque is ready
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To take its rightful place.
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00:21:00,724 --> 00:21:04,517
Workers spray the surface
With a coat of clear urethane.
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This prevents the brass
From tarnishing
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00:21:07,275 --> 00:21:09,137
And protects the plaque
From weathering
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When mounted outdoors.
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If you have any comments
About the show,
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00:21:23,793 --> 00:21:26,862
Or if you'd like to suggest
Topics for future shows,
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00:21:26,862 --> 00:21:29,862
Drop us a line at...
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