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In this episode... I can't tell you how
many times we sat around a table and
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said they wanted to do what?
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I think we still have to pinch ourselves
when we look at this building.
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The world's most slender skyscraper.
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No one has ever put together a project
as unique and as special as this.
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And the pioneering historic innovations.
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It's deflecting quite a bit. We have to
find another way to make it stiffer
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against the lateral force of the wind.
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I can't even imagine how windy it could
be here in a storm.
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The forces must be just enormous.
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That made the impossible possible.
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New York City is the most densely
populated city in the United States.
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The iconic island of Manhattan draws
millions from around the globe to live,
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work, and play, and its real estate is
among the most expensive in the world.
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Engineer John Schakalski is one of the
countless inhabitants that call the city
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that never sleeps home.
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So it's about 8 .6 million people all
trying to live in the same space in New
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York.
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It's incredible because there's never a
dull moment. There's always crowded
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streets.
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Everyone wants to live on the island of
Manhattan.
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And with nearly 3 million people
commuting to this 23 -square -mile
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day for work, engineers have nowhere
left to build but up.
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New York is synonymous with skyscrapers,
or the Woolworth Building, Chrysler
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Building, Empire State Building.
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So as the population continues to grow,
you need to come up with creative ways
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of how to build supertalls in Manhattan.
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Today, engineers are pushing the
boundaries of design and technology
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than ever before.
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is 111 West 57th Street.
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With unparalleled 360 -degree views of
Central Park in downtown Manhattan, this
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record -breaking skyscraper is the
thinnest building ever constructed.
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Designing a building like this is a once
-in -a -lifetime opportunity.
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This is definitely one of the most
complicated, if not the most
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residential buildings around the world
right now.
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What you don't see is all of the
engineering feats that are behind the
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You have all these different components
that are tied together that are just
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incredible.
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This gravity -defying giant marks the
dawn of a new age of skyscraper.
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It takes about seven and a half minutes
to get all the way up.
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It's a pretty nice ride.
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Going all the way up, Tommy.
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Once you clear all the surrounding lower
buildings at this height, it's another
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planet, another world.
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This is the reason why we're building
this.
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So right now we're standing higher than
any viewing platform in all of New York.
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When you're up at this elevation, you
got... 360 -degree views of everything
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surrounding Manhattan.
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You've got Central Park to the north,
Statue of Liberty, the Freedom Tower.
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It really is just breathtaking.
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111's daring construction team reach
heights few have ever been to.
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They are the only people to have ever
experienced the tower's unrivaled views
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over New York City.
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Up here, we have ironworkers. They're
bolting up, erecting the steel.
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It's pretty challenging up at 1 ,300
feet in the air, up to 1 ,400 feet. It's
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pretty intense.
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Every day, I'm blown away by the amount
of engineering and time and planning it
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goes into putting this type of a
building in place.
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Built over the historic Steinway Concert
Hall, 111 West 57th Street sits on an
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incredibly small plot of land.
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Once complete, this 84 -story, 1 ,428
-foot -tall building will be one of the
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tallest residential towers in the city.
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With a width -to -height ratio of 1 to
24, it is the thinnest skyscraper in the
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world. A mix of bronze, glass, and
terracotta cover the tower's enormous 1
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,257 -foot concrete sheer walls.
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At the top... A 170 -foot -high steel
crown will make this tower the second
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tallest residential building in the
Western Hemisphere.
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What gets me out of bed in the morning
is to take on the challenges of
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this, putting this job together, and
getting it to completion.
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So there's no rest until it's done.
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But this ambitious project poses serious
engineering challenges.
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How do you strengthen a skinny structure
without giving up floor space?
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The challenge is how do we get rid of
columns like this, minimize it, open up
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the floor space?
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You can't just take the columns out.
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There needs to be something there that
supports the actual structure itself.
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And how do you prevent such an
incredibly thin tower from collapsing in
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winds?
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Cynthia Liu and her structural
engineering team are experts in coming
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unconventional design solutions.
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As we can see here, this is the existing
Steinway building, and next to the
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Steinway building is the new plot we
have to work with.
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From this angle, you can really see how
narrow the new building is.
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Before construction began, engineers had
a 59 -foot wide site to build on.
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In order for the building to stand up
tall like this, we have to engineer it
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a way so the building can stay as is.
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As you can see, the building is slender
and it doesn't have a lot of footprint
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to sustain the load that applies to the
building.
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Most buildings will have the load
imposed on the rocks.
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But here, because the building is
slender and it has to take the wind
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the foundation of the building, there's
a lot of uplifting load.
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It needs to be engineered and taken care
of so the building doesn't fly away in
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the wind.
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Without a wide base to support the
tower, how can engineers brace it
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wind?
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To achieve the impossible, engineers
will need to draw inspiration from the
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pioneers of the past.
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Cork Harbor, a vast network of busy
shipping channels on the south coast of
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Ireland, where engineer Magda
Heidikevich is searching for a relic of
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navigation.
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For hundreds of years, the beautiful
Cork Harbor has been a very busy port.
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It was a gateway for trade and migration
and a very important naval base.
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The waterways connecting to the city are
very shallowed places and require
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careful navigation.
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Otherwise, the ships can run aground.
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There used to be floating lights to
indicate the shallow waters of Cork
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However, they would move around and can
be even destroyed in stormy conditions.
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A more permanent structure was needed to
withstand the force of the tide.
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Despite being blind since the age of 22,
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engineer Alexander Mitchell had no
problem visualizing a solution.
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In 1833, he patented a device that
enabled him to build a structure where
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could before.
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This is the Spitbank Lighthouse.
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It was built in 1853, 166 years ago, and
it still
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withstands the powerful forces of the
ocean.
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Protruding from the water on nine 46
-foot -long wrought iron stilts, this
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iconic beacon stands in stark contrast
to traditional stone lighthouses on the
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shore.
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00:09:06,350 --> 00:09:13,280
What Mitchell decided to do was place
nine stilts that would be sitting... on
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the seabed. However, that wasn't good
enough to withstand the powerful lateral
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forces of the tide and also lateral
forces of the wind.
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He had to extend those stills down to
the ground, but those stills could be
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pulled off from the ground. So he had to
anchor them down.
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So the very crucial part of the solution
are the ingenious anchors that Mitchell
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came up with.
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To secure the stilts 16 feet below the
seabed, Mitchell relied on his own
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brilliant invention.
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Drawing inspiration from the corkscrew,
he deployed crews on floating rafts to
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turn the supports and twist them into
the ground.
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Fastening the framework to the seafloor
has locked it in place against the
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wildest winds and waves.
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meters above the seabed. It's really
windy, very strong lateral wind forces
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tidal forces.
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I can't even imagine how it could be
here in a storm.
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The forces must be just enormous.
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But the structure is not going anywhere.
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It's very stable.
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The anchors holding this structure
stable in such strong wings would become
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handy when building a tall skyscraper.
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Spitbank Lighthouse has become an icon
for the city of Cork.
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Standing proud in the bay is testament
to the resilience of ground anchoring.
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When Mitchell designed the structure to
withstand the forces of waves and winds,
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he made it stronger than anyone could
have imagined.
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I doubt he thought that this structure
would still be here 166 years later.
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Mitchell's novel solution of anchoring
to the ground wasn't just meant for the
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sea. Today, when people want to build
taller, they have to take into account
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strong lateral forces that the structure
must withstand.
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What an amazing engineering solution.
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In Manhattan, engineers have taken
Mitchell's ground anchor concept and
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supersized it.
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in order to secure New York's third
largest tower to the ground.
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New York City is best known for its
iconic skyline.
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But in this densely populated
metropolis, Engineers are running out of
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build, so they are forced to come up
with an innovative solution that allows
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them to build not only super tall, but
super skinny.
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At 1 ,428 feet high, 111 West 57th
Street is the world's thinnest
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tower.
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This remarkable 84 -story residential
building features a 1 to 24 width to
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height ratio, soaring high above
Billionaire's Row.
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But securing New York's third tallest
tower to the ground is a major anchoring
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system challenge.
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So engineers have taken Alexander
Mitchell's ground anchoring concept to
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next level.
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Tasked with fastening the building in
place, engineer Cynthia Liu is heading
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down to the lowest accessible part of
the building.
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In order for the building not to tip
over, we have 192 rock anchors.
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This is the rock anchor that's used on
this job, which is, as you can see, it's
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pretty heavy, and it's hard to lift,
even a small piece like this.
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00:13:10,180 --> 00:13:13,500
And we have about 50 of them in this
wall here.
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The rock anchors we have here, we use
them as heavy as you can get on the
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market.
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Once the foundations of the historic
Steinway building are carefully
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and incredible 192 gigantic steel rods
are drilled nearly 80 feet down into the
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bedrock.
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In this case, they're not screwed in,
but instead they expand to lock into the
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rock. As lateral wind hits the tower,
the anchors can withstand a tremendous
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uplifting force of 57 ,320 tons.
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This is the design drawing that we
issued for this building.
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You can see all the little dots
representing the rock anchors.
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All the forces are transferred to the
rock anchors in the area.
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The rock anchors transfer to the rock
underneath, so the force is transferred
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from the top all the way to the bottom.
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Building on Mitchell's remarkable
concept, the team has installed one of
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highest concentrations of ground anchors
seen on any skyscraper in the world.
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Each rock anchor is about three inches
in diameter, and they vary from 50 feet
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to 75 feet deep below the rock. So
that's holding the building.
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Without the rock anchors, the building
definitely will turn over in the wind
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00:14:36,500 --> 00:14:39,760
load. So definitely we need the rock
anchors to hold the building down.
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00:14:41,040 --> 00:14:45,840
Now that a strong foothold has been
established, the Super Slender
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can rise into the clouds.
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The first stage of this megaproject is
complete, but engineers face more
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00:14:57,920 --> 00:14:59,260
impossible challenges.
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Sixty vast apartments will each occupy
at least one entire floor, as well as
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six two -story penthouses.
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But high winds equal high stakes.
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Even once secured into the rock, The
superstructure is exposed to the
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elements. Protecting it from bending and
breaking is the top priority for
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project director John Schakalski.
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So down here, we're about 50 feet down
below street level. And you can see that
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these massive columns act to take the
load of the structure from the wind and
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transfer it down floor to floor to floor
into the foundation.
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As you get into the superstructure where
you're trying to create these luxurious
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apartments with grand views of all of
Manhattan, you don't want a giant column
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like this in the middle of your living
room or dining room.
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So you can't just take the columns out.
You need something there to hold up the
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building.
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Both floor space and rigidity are
crucial in a residential high -rise.
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Defending the slender tower from
breaking in the wind might be impossible
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without the innovators of the past.
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Chicago, the Windy City.
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Known for a skyline punctuated by
soaring skyscrapers.
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This view never gets old.
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00:16:33,290 --> 00:16:35,070
It's one of the world's great skylines.
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00:16:36,830 --> 00:16:41,950
Architect and historian Tom Leslie is in
search of a daring innovation amongst
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00:16:41,950 --> 00:16:43,590
the city's towering giants.
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00:16:45,700 --> 00:16:50,340
Chicago is the city that really pushed
the development of tall buildings
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00:16:50,340 --> 00:16:51,480
than any other city.
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00:16:51,800 --> 00:16:54,540
This was a real laboratory for tall
building construction.
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00:16:56,500 --> 00:17:02,000
So the big development was to move away
from brick construction and to replace
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00:17:02,000 --> 00:17:03,000
that with steel.
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00:17:04,260 --> 00:17:09,560
As buildings get taller and taller, they
start to get so tall that the steel
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00:17:09,560 --> 00:17:13,940
frames are too flexible. They move too
much in the wind.
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And there's a limit to how tall you can
build a steel frame.
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Beyond that, engineers are looking for
another way to help stiffen the
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00:17:21,000 --> 00:17:22,000
buildings.
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00:17:23,500 --> 00:17:26,720
To demonstrate the problem, Tom has
scaled it down.
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So we have here a working wind tunnel
that's used to test skyscrapers, see how
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they respond to wind.
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00:17:34,860 --> 00:17:37,680
We're going to use it to test this model
of a frame.
230
00:17:37,900 --> 00:17:40,000
We have girders, we have beams.
231
00:17:40,320 --> 00:17:42,460
So we have here a curtain wall.
232
00:17:43,110 --> 00:17:47,530
It has no structural capability on its
own. It's very much like a glass skin
233
00:17:47,530 --> 00:17:49,730
that you would hang on the outside of
the structure.
234
00:17:52,270 --> 00:17:56,590
We've turned the wind on, and as you can
see, it's having quite an effect on our
235
00:17:56,590 --> 00:17:57,509
building frame.
236
00:17:57,510 --> 00:18:01,330
It's deflecting quite a bit, and it's
moving quite a lot. It's not a building
237
00:18:01,330 --> 00:18:03,410
any of us would ever want to be in.
238
00:18:03,670 --> 00:18:08,310
We have to find another way to help
stabilize it, to make it stiffer against
239
00:18:08,310 --> 00:18:09,670
lateral force of the wind.
240
00:18:11,050 --> 00:18:15,430
So one way we can stiffen the frame is
we can take pieces of the building that
241
00:18:15,430 --> 00:18:19,890
we already have, elevator cores, fire
stairs, things like that, and we can put
242
00:18:19,890 --> 00:18:25,750
very massive stiff core around them. But
a large core, or even column, take up
243
00:18:25,750 --> 00:18:27,030
valuable floor space.
244
00:18:29,550 --> 00:18:33,370
So what we've done is we've taken our
giant core, and we've put it right in
245
00:18:33,370 --> 00:18:34,570
middle of the building structure.
246
00:18:35,010 --> 00:18:40,050
It's bearing on several of the beams,
which in turn are sitting on the
247
00:18:40,540 --> 00:18:44,460
So you can see that the central core is
working. It's stabilizing the building.
248
00:18:44,640 --> 00:18:48,020
But you can also see that the frame is
still moving quite a bit.
249
00:18:48,240 --> 00:18:52,440
The other problem with such a massive
core is that it's taking up more space
250
00:18:52,440 --> 00:18:56,360
than we'd like. We're not able to rent
out the space that's within the core.
251
00:18:58,840 --> 00:19:03,000
When faced with the challenge of bracing
a tower without compromising floor
252
00:19:03,000 --> 00:19:08,350
space... Engineer Fazler Khan conceived
an ingenious way to utilize pre
253
00:19:08,350 --> 00:19:10,030
-existing structural components.
254
00:19:11,870 --> 00:19:17,070
His remarkable space -saving technique
was the shear wall interaction system.
255
00:19:17,590 --> 00:19:22,530
We can take the wind resistance that
that massive core has and spread it out
256
00:19:22,530 --> 00:19:24,710
into a pair of shear walls.
257
00:19:25,130 --> 00:19:28,990
tall planes that line each side of the
building and resist the wind.
258
00:19:29,250 --> 00:19:33,710
This spreads the resistance that the
core has out, which will give us the
259
00:19:33,710 --> 00:19:34,950
floor plates that we want.
260
00:19:35,670 --> 00:19:40,450
With rigid exterior walls, the size of
the inner core can be reduced.
261
00:19:40,870 --> 00:19:45,410
And Kahn's clever addition was to
connect the components with stiff
262
00:19:45,410 --> 00:19:48,790
floor plates so that the whole system
worked as one.
263
00:19:52,720 --> 00:19:57,040
We've turned the wind on, and as you can
see, all of the pieces of the building
264
00:19:57,040 --> 00:20:00,800
are working together. We're taking
advantage of the stiffness of the shear
265
00:20:00,800 --> 00:20:04,940
walls, the stiffness of the core, the
stiffness of the floor plates.
266
00:20:05,160 --> 00:20:09,800
All of them are working together to
create an integrated wind -resistant
267
00:20:13,460 --> 00:20:17,920
And Kahn was able to prove his theory
worked on a scale never seen before.
268
00:20:22,170 --> 00:20:27,910
is the Brunswick building, the world's
first tower to be supported by sheer
269
00:20:27,910 --> 00:20:28,910
interaction.
270
00:20:29,510 --> 00:20:33,590
The Brunswick's exterior structure is
four massive sheer walls.
271
00:20:33,790 --> 00:20:37,570
On the inside, there's a set of sheer
walls within the building core.
272
00:20:37,990 --> 00:20:40,430
To tie these two systems together,
273
00:20:41,170 --> 00:20:46,170
Kahn designed very, very stiff concrete
floors that ensure that when one system
274
00:20:46,170 --> 00:20:49,010
moves, the other system has to move as
well.
275
00:20:50,860 --> 00:20:55,120
things that were already there and so
the floor plates in the brunswick
276
00:20:55,120 --> 00:21:01,220
are all open between the core and the
exterior wall more than 80 percent of
277
00:21:01,220 --> 00:21:06,920
every floor is rentable which is an
incredibly high number for the era
278
00:21:06,920 --> 00:21:12,500
sheer wall interaction the brunswick
building opened in 1965 as the tallest
279
00:21:12,500 --> 00:21:15,120
reinforced concrete structure in the
world
280
00:21:15,850 --> 00:21:19,250
The Brunswick was a building that was
miles ahead of its time when it was
281
00:21:19,290 --> 00:21:23,230
and it's a building that was influential
for generations, even down to today.
282
00:21:35,410 --> 00:21:40,630
At New York's Guy High megastructure,
engineers are taking Kahn's pioneering
283
00:21:40,630 --> 00:21:42,050
technique to new heights.
284
00:21:44,840 --> 00:21:49,360
Just like in Chicago, they are bracing
the high -rise with a sheer wall
285
00:21:49,360 --> 00:21:52,200
interaction system on a colossal scale.
286
00:22:09,940 --> 00:22:15,120
111 West 57th Street is on track to
become the thinnest skyscraper in the
287
00:22:15,340 --> 00:22:19,800
But in order to endure high winds, it
will need a very sturdy structure.
288
00:22:20,140 --> 00:22:24,980
So engineers are bracing the high rise
with a shear wall interaction system.
289
00:22:26,780 --> 00:22:32,440
So here we are on the lower floors of
the actual superstructure, and you can
290
00:22:32,440 --> 00:22:37,440
how big the shear walls are. They're
over five feet thick down at the base of
291
00:22:37,440 --> 00:22:38,119
the building.
292
00:22:38,120 --> 00:22:39,120
They're pretty massive.
293
00:22:39,660 --> 00:22:46,240
The shear walls here extend about 60
feet below street level to 1 ,257 feet
294
00:22:46,240 --> 00:22:46,799
the air.
295
00:22:46,800 --> 00:22:48,980
They are some of the tallest shear walls
on the planet.
296
00:22:54,660 --> 00:23:01,060
The interaction system at 111 West 57th
Street has five shear walls all working
297
00:23:01,060 --> 00:23:02,059
in unison.
298
00:23:02,060 --> 00:23:05,440
The east and west walls form the
exterior structure.
299
00:23:05,840 --> 00:23:09,720
and flank three core shear walls,
including the elevator shaft.
300
00:23:10,460 --> 00:23:16,260
As 1 .3 million cubic feet of concrete
is poured one floor at a time, the
301
00:23:16,260 --> 00:23:22,660
configuration rises like an oversized I
-beam to over 1 ,247 feet high.
302
00:23:24,800 --> 00:23:29,380
As the mammoth shear walls climb to the
highest levels of the tower, they
303
00:23:29,380 --> 00:23:30,700
undergo a transformation.
304
00:23:34,190 --> 00:23:38,050
So here we are on one of the upper
duplexes in the tower.
305
00:23:38,630 --> 00:23:45,030
And as we get higher up in the building,
the sheer walls take a step in two
306
00:23:45,030 --> 00:23:48,430
directions. They lengthwise, they
shorten up, and widthwise.
307
00:23:49,470 --> 00:23:55,070
So you can imagine this wall was over
this wide down in the subcellar. And as
308
00:23:55,070 --> 00:23:58,810
you got up into the building, it's about
a foot and a half thick. By having
309
00:23:58,810 --> 00:24:02,850
thinner walls up top, it increases the
usable floor space.
310
00:24:04,250 --> 00:24:07,070
apartment space actually on the floor
plan.
311
00:24:09,050 --> 00:24:14,490
Not only do the shear walls taper in
width, they also take steps in length to
312
00:24:14,490 --> 00:24:16,450
create the tower's feathered profile.
313
00:24:17,110 --> 00:24:23,870
85 stiff concrete floors tie the system
together, forming one massive monolithic
314
00:24:23,870 --> 00:24:28,910
structure. Should wind hit from any
direction, the load is transferred
315
00:24:28,910 --> 00:24:29,990
the rigid components.
316
00:24:30,250 --> 00:24:33,750
downward into the 66 -foot thick
concrete foundations.
317
00:24:37,510 --> 00:24:42,030
So the giant columns you saw down in the
basement no longer exist up here, which
318
00:24:42,030 --> 00:24:43,570
opens up the entire floor space.
319
00:24:44,010 --> 00:24:50,010
By pushing the limit of concrete
construction, the monumental project at
320
00:24:50,010 --> 00:24:53,510
West 57th Street can climb into the sky.
321
00:24:54,090 --> 00:24:58,070
The shear walls act just so much more
than regular walls. They're transferring
322
00:24:58,070 --> 00:24:59,990
all the forces down into the foundation.
323
00:25:00,310 --> 00:25:03,070
Without the shear walls, there's no way
this building would have been possible.
324
00:25:04,210 --> 00:25:07,830
All the engineering that's gone into the
design of the shear walls, being able
325
00:25:07,830 --> 00:25:11,130
to handle all the outside forces, is
just unprecedented.
326
00:25:16,410 --> 00:25:21,790
With the monster shear walls topped out,
the building stands proud over New
327
00:25:21,790 --> 00:25:22,790
York.
328
00:25:24,200 --> 00:25:29,460
But left untouched, a colossal concrete
pillar could be an eyesore on the city
329
00:25:29,460 --> 00:25:30,460
skyline.
330
00:25:31,660 --> 00:25:36,940
Architect Dana Getman has a creative
solution to make the super -slender
331
00:25:36,940 --> 00:25:42,290
out. This tower is really unique in that
the east and west facades are the
332
00:25:42,290 --> 00:25:47,190
structure. And to really take advantage
of that, we clad it with this beautiful
333
00:25:47,190 --> 00:25:52,030
terracotta, which we designed with a
waving undulation of shapes that will
334
00:25:52,030 --> 00:25:56,270
create a shadow pattern as the sun casts
across the facade.
335
00:25:57,290 --> 00:26:01,730
When we started the design process, we
really looked at the DNA of New York
336
00:26:01,730 --> 00:26:06,790
buildings. We really wanted to get that
richness, but in a contemporary design.
337
00:26:07,630 --> 00:26:12,190
But the building's distinctive form
makes facade installation extremely
338
00:26:12,190 --> 00:26:13,190
challenging.
339
00:26:13,590 --> 00:26:18,290
It is unique to have double shear walls
on the exterior of your building. Most
340
00:26:18,290 --> 00:26:21,830
of the time when people install a
curtain wall, you slide it to the edge
341
00:26:21,830 --> 00:26:25,710
hang it from the floor above. But when
you're installing it on a shear wall,
342
00:26:25,830 --> 00:26:27,070
it's a little bit more complicated.
343
00:26:27,990 --> 00:26:30,470
With solid concrete obstructing the way.
344
00:26:30,960 --> 00:26:35,460
The team has come up with a one -of -a
-kind installation method to navigate
345
00:26:35,460 --> 00:26:37,020
unique wall configuration.
346
00:26:37,800 --> 00:26:44,480
The team here on site built a custom
gantry to be able to take the facade
347
00:26:44,480 --> 00:26:46,440
to their position on the shear wall.
348
00:26:49,720 --> 00:26:54,500
Once hooked up to the crane, facade
panels are flown out over the city
349
00:26:54,500 --> 00:26:56,080
hundreds of feet above the street.
350
00:26:58,350 --> 00:27:03,050
The enormous pieces are traversed around
the outside of the sheer walls to the
351
00:27:03,050 --> 00:27:06,510
installation team on the gigantic two
-stage hanging gantry.
352
00:27:07,770 --> 00:27:13,010
They have to change hands several times
in a precise and delicate procedure to
353
00:27:13,010 --> 00:27:15,430
fix them to the east and west sheer
walls.
354
00:27:18,010 --> 00:27:24,130
The result is a striking hybrid of New
York's Art Deco heritage with the
355
00:27:24,130 --> 00:27:25,830
-edge architecture of the future.
356
00:27:27,240 --> 00:27:32,320
I am incredibly impressed with the team
here on site and how smoothly the
357
00:27:32,320 --> 00:27:33,360
installation has gone.
358
00:27:33,840 --> 00:27:38,500
When you look at the building from a
distance, you see the waves of shadow
359
00:27:38,500 --> 00:27:41,120
you really see the impact of this
building on the skyline.
360
00:27:41,360 --> 00:27:43,120
We couldn't be happier with it.
361
00:27:48,580 --> 00:27:54,460
But to realize their dreams of creating
extraordinary apartments, engineers face
362
00:27:54,460 --> 00:27:55,580
yet another challenge.
363
00:27:56,360 --> 00:28:02,180
So our units are 15 foot 6 from floor to
floor, and that creates the need for a
364
00:28:02,180 --> 00:28:05,420
larger piece of glass in order to
maximize the views that we have.
365
00:28:06,100 --> 00:28:11,680
To create more impossible engineering,
the team will have to go back in time.
366
00:28:12,340 --> 00:28:13,920
Oh, wow, I can see the ripples.
367
00:28:14,920 --> 00:28:17,300
So that's the glass floating on the
team.
368
00:28:36,400 --> 00:28:41,580
Soaring over New York's prestigious
Billionaire's Row is the city's latest
369
00:28:41,580 --> 00:28:42,580
project.
370
00:28:47,060 --> 00:28:51,520
111 West 57th Street is the world's
thinnest skyscraper.
371
00:28:53,140 --> 00:28:57,900
Rising into the sky, it towers above the
neighbors and the city below.
372
00:29:01,240 --> 00:29:05,740
Construction of the third tallest tower
in New York is nearing completion.
373
00:29:06,730 --> 00:29:12,290
The project's final phase is underway,
preparing 60 luxury apartments for
374
00:29:12,290 --> 00:29:13,290
habitation.
375
00:29:14,990 --> 00:29:16,610
All right, are you going all the way up?
376
00:29:17,490 --> 00:29:18,490
Yeah.
377
00:29:18,870 --> 00:29:20,630
When you're done, we've got to pick up
on one.
378
00:29:21,070 --> 00:29:26,330
But to make the whole development
worthwhile, senior project manager Pat
379
00:29:26,330 --> 00:29:29,030
and his team have one last challenge to
conquer.
380
00:29:32,590 --> 00:29:35,810
So right now we're in Ahoyt, which runs
the north side of the building.
381
00:29:36,170 --> 00:29:40,110
You know, looking north from east to
west, we're dead center looking over
382
00:29:40,110 --> 00:29:42,650
Central Park. It's a pretty incredible
spot.
383
00:29:43,390 --> 00:29:46,950
The units that we have for this building
are going to be the only units on 57th
384
00:29:46,950 --> 00:29:49,550
Street that are going to have a dead
center view over Central Park.
385
00:29:50,530 --> 00:29:54,610
Pat's team must take advantage of the
tower's unrivaled views of the city.
386
00:29:55,050 --> 00:29:58,970
Not an easy mission to accomplish in
such enormous living spaces.
387
00:30:01,230 --> 00:30:04,650
So our units are 15 foot 6 from floor to
floor.
388
00:30:04,910 --> 00:30:09,310
That creates the need for a larger piece
of glass in order to maximize the views
389
00:30:09,310 --> 00:30:10,109
that we have.
390
00:30:10,110 --> 00:30:13,870
We need to find a solution to make sure
that we can see them perfectly from the
391
00:30:13,870 --> 00:30:14,870
units.
392
00:30:15,070 --> 00:30:21,010
To find vast window panes worthy of the
unprecedented panoramic youth, the team
393
00:30:21,010 --> 00:30:23,050
must look to the pioneers of the past.
394
00:30:31,600 --> 00:30:33,640
St. Helens in the north of England.
395
00:30:35,000 --> 00:30:36,980
Legendary for industrial innovation.
396
00:30:37,780 --> 00:30:42,340
Where physicist Susie Sheehy is heading
underground in search of a development
397
00:30:42,340 --> 00:30:44,600
that shook the world of glass
production.
398
00:30:48,220 --> 00:30:52,200
These tunnels are actually below a glass
melting furnace.
399
00:30:52,520 --> 00:30:56,860
And all around here there would have
been coal fires that would have been so
400
00:30:56,860 --> 00:30:58,540
for the workers working down here.
401
00:30:59,120 --> 00:31:03,640
What they were aiming for was to make
large panes of glass for windows that
402
00:31:03,640 --> 00:31:06,300
clear and strong and free of blemishes.
403
00:31:06,700 --> 00:31:12,580
So they'd take molten glass and pour it
over a metal tray where it would cool
404
00:31:12,580 --> 00:31:16,920
down. But the result was something that
was imperfect. It was blemished and
405
00:31:16,920 --> 00:31:20,260
rough. So then they'd have to grind and
polish it.
406
00:31:20,860 --> 00:31:25,440
Even then, the panes they made were not
super big. It was only up to a couple of
407
00:31:25,440 --> 00:31:29,950
metres. So to get something even bigger
and better, they'd actually have to come
408
00:31:29,950 --> 00:31:31,590
up with a totally new solution.
409
00:31:33,810 --> 00:31:38,070
But for Sir Alistair Pilkington, the
answer was crystal clear.
410
00:31:39,170 --> 00:31:43,570
In the 1950s, he developed a
revolutionary new process.
411
00:31:45,990 --> 00:31:52,230
So this place is the solution that
Pilkington came up with. And it's
412
00:31:52,230 --> 00:31:54,870
incredible. I've just seen in front of
me here this huge...
413
00:31:55,070 --> 00:31:59,910
really flat sheet of glass absolutely
beautiful
414
00:31:59,910 --> 00:32:05,530
Pilkington's float glass innovation
415
00:32:05,530 --> 00:32:12,430
quite literally broke the mold it's so
flat because they pour
416
00:32:12,430 --> 00:32:18,910
molten glass onto a bar of molten tin
and that's so flat that it comes out in
417
00:32:18,910 --> 00:32:21,610
these enormous sheets they're just
incredible
418
00:32:23,280 --> 00:32:28,320
This cutting -edge plant has modernized
its machinery, but remains true to
419
00:32:28,320 --> 00:32:29,500
Pilkington's technique.
420
00:32:29,880 --> 00:32:30,960
Oh, wow.
421
00:32:31,280 --> 00:32:33,820
I can feel the heat radiating off this.
422
00:32:34,520 --> 00:32:39,840
For any glass production process, a sand
-based mixture must first be melted to
423
00:32:39,840 --> 00:32:43,340
a scorching 2 ,912 degrees Fahrenheit.
424
00:32:43,700 --> 00:32:48,200
But what sets this extraordinary method
apart is what happens next.
425
00:32:48,700 --> 00:32:49,700
Woo!
426
00:32:50,320 --> 00:32:51,320
Nice.
427
00:33:07,850 --> 00:33:14,710
In the 1950s, Sir Alistair Pilkington
invented the float glass process, a
428
00:33:14,710 --> 00:33:18,410
revolutionary method to manipulate the
size and thickness of glass.
429
00:33:19,070 --> 00:33:24,750
After a sand -based mixture is melted at
nearly 3 ,000 degrees, it is fed into a
430
00:33:24,750 --> 00:33:26,350
molten tin bath chamber.
431
00:33:27,430 --> 00:33:30,530
So this is about 25 kg, so it's quite
heavy.
432
00:33:30,950 --> 00:33:33,290
We just step to the side and place it
into the box.
433
00:33:36,450 --> 00:33:37,449
That's amazing.
434
00:33:37,450 --> 00:33:39,030
And now I get to push it in.
435
00:33:39,250 --> 00:33:41,050
Yeah, if you just stand back, just push
it gently in.
436
00:33:42,590 --> 00:33:43,590
That's it.
437
00:33:44,430 --> 00:33:46,210
Did I do?
438
00:33:46,770 --> 00:33:47,770
All right.
439
00:33:48,230 --> 00:33:50,390
Just leave it there, and you'll see it
melted away now.
440
00:33:50,890 --> 00:33:55,210
Oh, wow. I can see the ripples. Yeah,
yeah, that's the tin. So that's the
441
00:33:55,210 --> 00:33:57,690
bath of milk? That's the actual tin.
That's what the glass is called. Wow.
442
00:33:58,650 --> 00:34:01,730
If you look at it straight up there,
that line that you can see, that's the
443
00:34:01,730 --> 00:34:05,390
actual glass there. So that's the glass
floating on the tin. It just looks like
444
00:34:05,390 --> 00:34:06,009
a mirror.
445
00:34:06,010 --> 00:34:07,010
Does, yeah? Yeah.
446
00:34:09,570 --> 00:34:12,850
As a liquid, molten tin sits perfectly
flat.
447
00:34:14,690 --> 00:34:18,070
Glass from the furnace is slowly poured
over the lake of metal.
448
00:34:18,550 --> 00:34:23,590
And being less dense than the tin, it
floats atop the surface, spreading and
449
00:34:23,590 --> 00:34:25,810
cooling in a flawlessly smooth sheet.
450
00:34:27,630 --> 00:34:32,670
The glass leaves the bath with so few
impurities that it's crystal clear and
451
00:34:32,670 --> 00:34:33,790
incredibly strong.
452
00:34:34,050 --> 00:34:37,210
Properties that would make for great
skyscraper windows.
453
00:34:38,230 --> 00:34:41,929
So this section is where the solid glass
comes out.
454
00:34:42,170 --> 00:34:46,929
And it's really beautiful and flat and
clear, perfect for windows.
455
00:34:47,290 --> 00:34:51,370
But when they first started using this
float method, they had glass that was
456
00:34:51,370 --> 00:34:52,469
just six meters long.
457
00:34:52,690 --> 00:34:57,010
But now... They've perfected it to the
point where they can just get a
458
00:34:57,170 --> 00:35:01,870
unbroken flow of glass over this 600
-meter length.
459
00:35:02,150 --> 00:35:07,430
And this one here, it works 24 hours, 7
days a week, and hasn't switched off for
460
00:35:07,430 --> 00:35:08,730
more than 7 years.
461
00:35:09,010 --> 00:35:10,230
It's so reliable.
462
00:35:10,550 --> 00:35:11,850
It's an unbelievable method.
463
00:35:12,430 --> 00:35:19,070
The float line can run continuously for
20 years, producing around 479 million
464
00:35:19,070 --> 00:35:21,930
feet of glass, enough to wrap around the
Earth.
465
00:35:22,200 --> 00:35:24,160
three and a half thousand times.
466
00:35:24,360 --> 00:35:29,000
So as it comes out here, I can't see a
single imperfection in these panes.
467
00:35:29,300 --> 00:35:31,960
This method just produces perfect glass.
468
00:35:32,420 --> 00:35:35,980
And that's only possible because of this
slow glass method.
469
00:35:47,780 --> 00:35:51,100
70 years after Pilkington's inspired
idea.
470
00:35:52,430 --> 00:35:57,390
New York's greatest engineering minds
are using float glass to provide views
471
00:35:57,390 --> 00:35:59,030
unlike any other on Earth.
472
00:36:02,690 --> 00:36:08,150
Pat Feehan is overseeing the
installation of 111 supersized insulated
473
00:36:08,150 --> 00:36:12,410
units. So on the exterior facade, this
is the exterior facade of the glass.
474
00:36:12,650 --> 00:36:15,670
So there's three individual pieces of
float glass made up into these glazed
475
00:36:15,670 --> 00:36:19,570
units. They have two pieces of laminated
glass on the exterior facade.
476
00:36:19,900 --> 00:36:24,280
And then one piece of a slightly larger,
thicker glass on the interior beside
477
00:36:24,280 --> 00:36:26,040
with a 12 -millimeter argon gap.
478
00:36:26,960 --> 00:36:30,500
The technology that goes into the glass
in particular allow us to make the
479
00:36:30,500 --> 00:36:33,380
panels that we can make today. And if it
wasn't for the float glass, we wouldn't
480
00:36:33,380 --> 00:36:34,380
be able to make panels like this.
481
00:36:35,720 --> 00:36:40,720
The tower's massive glass panels owe
their immense strength and clarity to
482
00:36:40,720 --> 00:36:41,840
float glass method.
483
00:36:42,320 --> 00:36:44,400
To the actual essence of the glass
itself.
484
00:36:44,710 --> 00:36:48,430
Pretty fundamental, but the technology
that's come around along it that have
485
00:36:48,430 --> 00:36:52,750
allowed us to get larger panes of glass,
stronger glass, to allow us to push the
486
00:36:52,750 --> 00:36:54,070
material as far as we can go.
487
00:36:56,810 --> 00:37:01,770
Although each apartment has solid east
and west sheer walls, they're completely
488
00:37:01,770 --> 00:37:03,430
open to the north and south.
489
00:37:03,730 --> 00:37:10,130
The team's task is to fill a void over
59 feet wide and nearly 16 feet high on
490
00:37:10,130 --> 00:37:13,630
each floor with huge panels of crystal
clear glass.
491
00:37:13,870 --> 00:37:15,950
to minimize view -obstructing joints.
492
00:37:16,170 --> 00:37:20,610
The largest panel, which will form the
centerpiece of each apartment, weighs
493
00:37:20,610 --> 00:37:23,790
over one ton, as much as a small car.
494
00:37:27,950 --> 00:37:32,390
Installing these massive window panes at
extreme heights is an intense
495
00:37:32,390 --> 00:37:33,390
operation.
496
00:37:35,330 --> 00:37:40,150
And the team will have to carefully pull
off a daring act of engineering.
497
00:37:57,270 --> 00:38:02,830
In New York City, engineers are
preparing to install massive glass
498
00:38:02,830 --> 00:38:05,770
on a groundbreaking new residential
skyscraper.
499
00:38:07,050 --> 00:38:09,630
So right now we're getting ready to
install this panel, so we're going to be
500
00:38:09,630 --> 00:38:10,810
flying it out from this floor.
501
00:38:11,010 --> 00:38:13,550
The tower crane's going to come down
with the hook. We're going to hook it
502
00:38:13,570 --> 00:38:16,510
and we're going to send that panel out
and install until 69.
503
00:38:17,810 --> 00:38:22,170
It's not a typical install because the
panel is so large, gets caught in the
504
00:38:22,170 --> 00:38:23,610
wind, it could flow around.
505
00:38:25,060 --> 00:38:27,320
Everyone has to be on their game a
little bit more.
506
00:38:28,540 --> 00:38:31,680
To be doing this work, you have to be
able to deal with the heights and be
507
00:38:31,680 --> 00:38:34,920
to deal with working on the slab edge,
which is not an easy thing to do.
508
00:38:37,740 --> 00:38:42,760
The fearless installation team pushes
extreme construction to the very edge.
509
00:38:43,860 --> 00:38:48,100
The oversized heavyweight panel is
lowered five floors down.
510
00:38:48,980 --> 00:38:51,460
One wrong move could spell catastrophe.
511
00:38:52,030 --> 00:38:55,130
We're going down to level 69 where this
panel's going to get installed.
512
00:38:55,650 --> 00:39:00,710
With the success of the installation
hanging in the balance, the team needs
513
00:39:00,710 --> 00:39:04,690
work quickly to secure the panel into
the interlocking weather seal.
514
00:39:04,930 --> 00:39:05,930
Hold that.
515
00:39:11,490 --> 00:39:16,090
So, you know, we have one panel now
installed of over 6 ,500 total on the
516
00:39:16,090 --> 00:39:17,090
building.
517
00:39:18,230 --> 00:39:21,410
And selling panels one at a time, you
know, it doesn't feel like you're
518
00:39:21,410 --> 00:39:25,170
anywhere, but after a while, they start
to add up. We're on the 69th floor right
519
00:39:25,170 --> 00:39:27,950
now, installing panels. We're
approaching the end, which is kind of
520
00:39:28,650 --> 00:39:32,810
There's a lot of amazing things about
111 West 57th Street, but I think one of
521
00:39:32,810 --> 00:39:35,390
the key things and one of the biggest
selling points is the view that we have
522
00:39:35,390 --> 00:39:39,890
here. The technology that has gone into
making glass has progressed so much over
523
00:39:39,890 --> 00:39:43,750
time that it allows us to make panels
the size that we have here, to have them
524
00:39:43,750 --> 00:39:46,190
as clear as they are, to have the views
that we have.
525
00:39:46,520 --> 00:39:49,500
You know, we have the whole entire
skyline to look at. It's kind of
526
00:39:57,700 --> 00:40:02,340
For the team behind this daring project,
the engineering achievement is
527
00:40:02,340 --> 00:40:03,340
immeasurable.
528
00:40:03,960 --> 00:40:06,940
Looking at a postcard 20 years from now
at the skyline of Manhattan, it's going
529
00:40:06,940 --> 00:40:08,860
to be a building that I built on that.
It's kind of incredible.
530
00:40:10,190 --> 00:40:12,790
Every day we look at the building, see
it grow.
531
00:40:13,130 --> 00:40:18,670
It's really incredible, and we feel like
very lucky to be part of the team to
532
00:40:18,670 --> 00:40:19,670
work on this.
533
00:40:20,850 --> 00:40:25,210
No matter which aspect you look at this
building, it has definitely enhanced the
534
00:40:25,210 --> 00:40:30,190
New York City skyline. It's taken pieces
of old New York and new New York and
535
00:40:30,190 --> 00:40:33,590
combined them together and created
something that the world has never seen
536
00:40:33,590 --> 00:40:34,590
before.
537
00:40:43,340 --> 00:40:47,140
The super -slender skyscraper that has
defied the impossible.
538
00:40:48,380 --> 00:40:52,600
Pushing the limits on tower construction
further than ever before.
539
00:40:53,100 --> 00:40:59,020
A new landmark vanishing into the
clouds, changing New York's skyline
540
00:41:00,320 --> 00:41:04,880
Standing testament to the incredible
work of some of New York's greatest
541
00:41:04,880 --> 00:41:06,060
engineering minds.
542
00:41:17,970 --> 00:41:24,030
111 West 57th Street represents
impossible engineering on a staggering
543
00:41:25,650 --> 00:41:30,870
Every stage of this groundbreaking
enterprise poses unimaginable
544
00:41:36,030 --> 00:41:39,450
When we first started this project, I
knew we were doing something special.
545
00:41:39,650 --> 00:41:44,430
This is one of the most unique
superstructures that you could ever put
546
00:41:45,130 --> 00:41:50,850
But by building on the work of the
pioneers of the past, overcoming huge
547
00:41:50,850 --> 00:41:54,690
challenges, and pushing the boundaries
of innovation.
548
00:41:55,030 --> 00:41:58,770
I'm incredibly proud to be working on
this project. It's incredible, and it's
549
00:41:58,770 --> 00:41:59,810
more than I could have asked for.
550
00:42:01,110 --> 00:42:06,290
We really saw it as an opportunity to do
something that both spoke to the past,
551
00:42:06,390 --> 00:42:10,990
but also looked to the future, and to
see it not just through design, but now
552
00:42:10,990 --> 00:42:11,990
almost complete.
553
00:42:12,680 --> 00:42:15,620
physically here is really an incredible
experience.
554
00:42:16,400 --> 00:42:22,580
The engineers are succeeding in making
the impossible possible.
555
00:42:22,630 --> 00:42:27,180
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