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Narrator: What happens

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when the world's
most radical architect

3
00:00:06,765 --> 00:00:08,731
tries to revive a
hundred-year-old building?

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Man: This project
obviously stands and falls

5
00:00:11,632 --> 00:00:14,530
with structure.

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I mean, this is a
structural masterpiece.

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Narrator: How is
one of the world's

8
00:00:18,225 --> 00:00:19,639
tallest residential skyscrapers

9
00:00:19,640 --> 00:00:21,745
even standing?

10
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Man: Columns are what
make a building stand up.

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You take away that
structural support

12
00:00:27,579 --> 00:00:29,650
and...[imitates explosion]

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Narrator: And how do
you create a building

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that would have been
impossible just 10 years ago?

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Woman: Building in water

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is incredibly difficult.

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You've gotta hold
back an entire river

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while you're building.

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Narrator: This is the
age of the extraordinary...

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Man: This house always is
on the verge of falling down.

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Narrator: Where
ingenious engineers

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have unleashed
unchecked creativity...

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Woman: Everything
in this building

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pushes at the boundaries
of what's possible.

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Narrator: Building
structures so outrageous,

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they defy logic.

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Woman: The forces on this thing

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look like it should
be torn apart.

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Narrator: Now their
secrets are revealed.

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Discover the incredible
stories of their construction...

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Woman: These are
extraordinary feats of engineering.

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Narrator: To try and understand

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how did they build that?

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Ever-growing cities are in
a constant battle for space,

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risking demolishing the
old to make way for the new.

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But in antwerp, Belgium,
one of Europe's busiest ports,

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a forgotten
100-year-old building

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has been transformed
beyond imagination.

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A ground-breaking architect
has turned this historic firehouse

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into a landing pad
for an extension

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that is truly out of this world,

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challenging engineers to float
the new addition effortlessly

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above the original building...

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Hayley loren oakes: It leans
forwards, it's backwards,

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it's completely off
centre on the legs.

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Narrator: Manufacturing
the entire structure off-site,

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and then shipping it in
massive 400-ton pieces.

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Ellie cosgrave: We're
dealing with making sure

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we protect this
precious building

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that lies underneath.

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Narrator: Breathing new life
into every inch of its new home.

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This is the antwerp port house.

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So, how did they build it?

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The antwerp port authority,

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the government body
that controls the busy port,

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needed a new home.

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They decided on a
long-forgotten firehouse

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in the centre of the
industrial complex.

59
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It needed some serious work

60
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if it was going to function
as their new headquarters,

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but they didn't want to demolish
the original listed building.

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Joshua macabuag: Adding
to existing historical structures

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is a real challenge.

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You've got the
technical challenge

65
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of being able to work
around and load and repair

66
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what can be quite old
and historic material

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of the building.

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But then you've
also got the aesthetic

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and the kind of
heritage issues as well.

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You need to build something

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that's gonna be true
to the original history

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and aesthetic of the structure

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or complement it in quite
a stark and interesting way.

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Narrator: They brought in

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one of the world's
most famous architects,

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zaha hadid,

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to come up with a solution.

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Her visionary designs, like
the Guangzhou opera house,

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were known for pushing
engineering to the limits.

80
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It needed some serious work

81
00:04:06,522 --> 00:04:08,642
if it was going to function
as their new headquarters.

82
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But they didn't want to
demolish the original building.

83
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Joris pauwels: This is maybe
the biggest and most prominent

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00:04:17,947 --> 00:04:20,189
existing building we've taken on

85
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to develop into a
new overall project,

86
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@and it's definitely
a challenge,

87
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but it's something
that we relish,

88
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it gives all kinds
of new perspectives

89
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on how to deal with
existing fabric, urban fabric.

90
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Narrator: They had to figure out

91
00:04:35,723 --> 00:04:37,276
how to build a
futuristic extension

92
00:04:37,277 --> 00:04:39,071
to create a space
to house new offices,

93
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while protecting a
beautiful historic building

94
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that would form the
rest of the port authority's

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new headquarters.

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Joris: The original design

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had four equal facçades,

98
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meaning there's
no front entrance.

99
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The four sides were
equally important,

100
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so we definitely
wanted to preserve

101
00:04:59,160 --> 00:05:00,748
that quality of the
existing building

102
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by building a volume on top

103
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and not blocking visually
one of the main facçades.

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Narrator: The
architects also wanted

105
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to preserve the building's
central courtyard.

106
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Conservation specialist
Philippe lemineur

107
00:05:17,593 --> 00:05:19,833
was charged with protecting
this piece of antwerp's past,

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making sure the radical
design didn't destroy the building

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or Rob it of its
original identity.

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Philippe lemineur: We
can see in the typology

111
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of a fire station
a lot of elements.

112
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One you can see
on the right side

113
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is that there are a lot
of gates for fire trucks,

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and then you have the back
side in the middle of the facçade,

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the dry tower.

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Those elements are very
important for a fire station.

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Narrator: Studying the
plans for the firehouse

118
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gave the architects an idea...

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One that would honour
the original design

120
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and let them build
something out of this world.

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It turns out the building
was never actually finished.

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Joris: It was built in 1921,

123
00:06:10,680 --> 00:06:12,360
and the original
design of the fire station

124
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had a big tower on top,

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which was twice the
size of the building,

126
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very extravagant,
was never built,

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and which made us consider

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an extension on top
of the existing building

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as a kind of
contemporary endpoint

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to the existing building.

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Narrator: This
monumental extension

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not only brings the building
into the 21st century;

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it completes the vision
of the original architect.

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The plan was to build

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a precision-engineered
futuristic extension

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over 60 feet above
the historic building

137
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to house new offices,

138
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supporting the
1,500-ton structure

139
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with two massive concrete legs,

140
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and to join the new
extension to the firehouse

141
00:07:03,181 --> 00:07:05,977
through the old tower,

142
00:07:07,288 --> 00:07:09,163
where the firemen used
to hang their hoses to dry.

143
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The engineers got to work

144
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figuring out how to support
the massive steel structure

145
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above the 100-year-old building,

146
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without damaging it.

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Joris: This project obviously
stands and falls with structure.

148
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I mean, this is a
structural masterpiece.

149
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We'd like our buildings
to float if we can,

150
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so we definitely try
to minimize the points

151
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and keep this
idea of a hovering,

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large hovering volume
over the existing building.

153
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The new building cantilevers out

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over the square in front
of the existing building.

155
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It's quite a dramatic effect,

156
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pointing towards the
city centre of antwerp.

157
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The structure of
the new building

158
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is a steel structure.

159
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It's held by two
concrete pillars.

160
00:08:01,239 --> 00:08:02,860
Narrator: The engineers
built two concrete legs

161
00:08:02,861 --> 00:08:04,587
to hold up the new offices,

162
00:08:05,933 --> 00:08:07,773
with the front leg
designed to widely lean out.

163
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It looked dramatic,

164
00:08:12,112 --> 00:08:13,595
but without
precise calculations,

165
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it risked dropping
the brand-new building

166
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on top of the firehouse.

167
00:08:19,568 --> 00:08:21,768
Ellie: Because the front
leg is leaning out at an angle,

168
00:08:22,743 --> 00:08:25,435
it's gonna want to
push out at the top

169
00:08:26,644 --> 00:08:28,284
and slip under the
building at the bottom.

170
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Narrator: They decided to
connect the front and back legs

171
00:08:32,546 --> 00:08:34,928
at the top and bottom,

172
00:08:36,239 --> 00:08:38,309
turning the structure into
a massive concrete ring,

173
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with the bottom part of
that ring underground.

174
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Corina kwami: By connecting
these two legs at the top,

175
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they are kept from
falling out at the top,

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and at the bottom,
stopped from slipping in.

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Joris: The two pillars
are obviously not vertical,

178
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so that we have a very
dramatically inclined

179
00:08:57,709 --> 00:08:59,469
front pillar,

180
00:09:00,332 --> 00:09:01,885
which needs the concrete ring

181
00:09:01,886 --> 00:09:03,446
to keep it from falling
over the square,

182
00:09:04,198 --> 00:09:05,855
so that's why this
ring is very important

183
00:09:06,580 --> 00:09:08,064
as a structural element.

184
00:09:09,928 --> 00:09:12,103
Narrator: The ring is joined

185
00:09:13,414 --> 00:09:14,691
just under the massive
steel and glass structure,

186
00:09:14,692 --> 00:09:16,866
and the bottom
connects these stories

187
00:09:17,729 --> 00:09:19,592
underground in the carpark,

188
00:09:19,593 --> 00:09:22,043
keeping the legs in place

189
00:09:22,044 --> 00:09:23,907
and letting them support
the weight of the extension.

190
00:09:23,908 --> 00:09:26,669
The top section stops the giant
concrete leg from falling over,

191
00:09:28,568 --> 00:09:32,191
and the bottom
stops it sliding out

192
00:09:32,192 --> 00:09:33,712
from under the
massive steel structure.

193
00:09:34,677 --> 00:09:37,024
The whole thing is
steadied by another four

194
00:09:38,060 --> 00:09:39,380
internal-connected
steel supports.

195
00:09:41,304 --> 00:09:44,066
The engineers did all this

196
00:09:45,274 --> 00:09:46,834
while barely touching
the old firehouse.

197
00:09:50,417 --> 00:09:54,178
Joris: We tried
to keep the impact

198
00:09:54,179 --> 00:09:55,767
on the existing
building very minimal,

199
00:09:56,665 --> 00:09:58,701
and that is equally important

200
00:09:59,806 --> 00:10:01,082
when we created
this structural ring,

201
00:10:01,083 --> 00:10:02,774
which goes through
the foundation work

202
00:10:03,603 --> 00:10:05,605
of the existing building,

203
00:10:06,709 --> 00:10:09,435
so it's a very
minimal connection,

204
00:10:09,436 --> 00:10:11,057
both structurally, where
we connect the foundations,

205
00:10:11,058 --> 00:10:13,854
as well as physically

206
00:10:15,062 --> 00:10:16,580
where we introduced
the small staircase

207
00:10:16,581 --> 00:10:18,981
leading up to the entrance
hall inside the existing building.

208
00:10:22,311 --> 00:10:24,111
We've got a two-story
underground car parking,

209
00:10:24,313 --> 00:10:27,074
so it's two stories down.

210
00:10:27,661 --> 00:10:29,697
Underneath that,

211
00:10:29,698 --> 00:10:30,905
so the third basement
level, if you like,

212
00:10:30,906 --> 00:10:32,492
that's where we
made the connection

213
00:10:32,493 --> 00:10:34,460
between the foundation
of that inclined front pillar

214
00:10:34,461 --> 00:10:36,541
and the central pillar,
which rests in the courtyard.

215
00:10:39,915 --> 00:10:41,955
Narrator: What did the
conservation specialist think

216
00:10:42,262 --> 00:10:44,540
of this radical approach?

217
00:10:45,817 --> 00:10:47,497
Did it do justice to
the original building?

218
00:10:49,200 --> 00:10:51,892
Philippe: The opportunity
to do the second feet

219
00:10:53,238 --> 00:10:55,118
at the inside of the
building, in the courtyard.

220
00:10:56,310 --> 00:10:59,072
But we still needed to have
the aspect of a courtyard.

221
00:11:01,074 --> 00:11:03,870
You can't fill it up with
feets and structure.

222
00:11:04,733 --> 00:11:06,735
Then you have no more courtyard,

223
00:11:07,839 --> 00:11:09,737
and you have no
more light inside.

224
00:11:09,738 --> 00:11:12,740
You can use even
more this space.

225
00:11:12,741 --> 00:11:15,501
So the engineer and zaha
hadid tried to find a way

226
00:11:15,502 --> 00:11:18,987
that you could
have this structure,

227
00:11:18,988 --> 00:11:21,819
but with the kind of subtlety

228
00:11:23,130 --> 00:11:25,050
that these are sculptural
elements in the inside,

229
00:11:25,236 --> 00:11:26,962
and so, you can see
that those elements,

230
00:11:28,066 --> 00:11:31,137
even not touch
the old structure...

231
00:11:31,138 --> 00:11:33,071
Just landing
inside the building,

232
00:11:34,555 --> 00:11:36,875
and they make possible that
this big volume above our heads

233
00:11:38,214 --> 00:11:41,045
is standing over there.

234
00:11:43,426 --> 00:11:47,188
Narrator: With the gigantic
concrete legs in place,

235
00:11:47,189 --> 00:11:49,949
the engineers
were ready to tackle

236
00:11:49,950 --> 00:11:52,572
the futuristic glass structure.

237
00:11:52,573 --> 00:11:55,161
But constructing it was going
to be a bigger undertaking

238
00:11:55,162 --> 00:11:57,958
than anyone had imagined.

239
00:11:59,339 --> 00:12:01,339
Joris: Having the new
building floating in mid-air,

240
00:12:02,031 --> 00:12:04,231
it's important that it's not a
super heavy construction.

241
00:12:04,516 --> 00:12:06,518
So it's a steel structure.

242
00:12:07,554 --> 00:12:09,279
It also is a
sustainable structure.

243
00:12:09,280 --> 00:12:11,200
So we looked at the whole
number of possibilities

244
00:12:11,834 --> 00:12:13,802
of constructing the building.

245
00:12:15,010 --> 00:12:16,458
We did a lot of analysis
with the contractor

246
00:12:16,459 --> 00:12:18,013
to see how they
could build platforms,

247
00:12:19,186 --> 00:12:20,826
how they could get
enough people up there.

248
00:12:24,191 --> 00:12:25,709
Narrator: To preserve
the original building

249
00:12:25,710 --> 00:12:28,816
and realize the precise design,

250
00:12:28,817 --> 00:12:31,257
the engineers decided to build
almost all of the new extension

251
00:12:31,923 --> 00:12:34,788
in a factory 55 miles away.

252
00:12:36,100 --> 00:12:38,827
Joris: It was clear,
after initial analysis,

253
00:12:40,069 --> 00:12:41,932
that building the
steel structure off-site

254
00:12:41,933 --> 00:12:43,521
in big modules,

255
00:12:44,764 --> 00:12:46,523
shipping them to site,
and installing them

256
00:12:46,524 --> 00:12:48,124
was a much faster and
more economical way

257
00:12:48,975 --> 00:12:51,148
of constructing the building.

258
00:12:51,149 --> 00:12:52,910
Corina: Normally
with steel structures,

259
00:12:54,083 --> 00:12:54,843
you build upwards
with scaffolding support

260
00:12:54,844 --> 00:12:56,741
and welding as you go.

261
00:12:57,397 --> 00:12:59,639
But in this case,

262
00:12:59,640 --> 00:13:00,779
they were building over
the existing structure.

263
00:13:00,780 --> 00:13:03,609
You're looking at a lot
of scaffolding support,

264
00:13:03,610 --> 00:13:05,956
with all the risks of
building over and around

265
00:13:05,957 --> 00:13:08,684
this listed precious building.

266
00:13:09,374 --> 00:13:10,790
So what do you do?

267
00:13:12,067 --> 00:13:14,067
You build it 90 kilometres
away, in 400-ton pieces,

268
00:13:14,379 --> 00:13:17,175
and ship it in.

269
00:13:19,419 --> 00:13:21,459
Joris: So building the
structure of the new building

270
00:13:21,801 --> 00:13:24,423
off-site in factory

271
00:13:24,424 --> 00:13:26,563
means it's much more
controlled in terms of tolerances,

272
00:13:26,564 --> 00:13:28,244
making sure everything
is completely right.

273
00:13:29,256 --> 00:13:30,856
They even installed
a temporary structure

274
00:13:31,741 --> 00:13:33,501
to ship the modules
on boats to the location,

275
00:13:35,262 --> 00:13:37,955
and then all they had
to do is lift them in place,

276
00:13:39,232 --> 00:13:40,819
so it's a much faster
construction procedure

277
00:13:40,820 --> 00:13:42,718
to build the overall volume.

278
00:13:43,823 --> 00:13:45,103
The structure of
the new building

279
00:13:45,997 --> 00:13:46,929
is built in six
separate steel parts,

280
00:13:46,930 --> 00:13:49,967
two steel pieces per level,

281
00:13:50,864 --> 00:13:53,210
and they were lifted in place

282
00:13:53,211 --> 00:13:54,556
and then assembled on
top of the existing building.

283
00:13:54,557 --> 00:13:57,077
Narrator: The
330-foot-long, 200-foot-high,

284
00:13:59,700 --> 00:14:02,634
and 65-foot-wide steel structure

285
00:14:03,877 --> 00:14:05,677
was broken up into six
enormous 400-ton pieces

286
00:14:07,398 --> 00:14:10,159
and shipped from the factory 55
miles away on massive barges.

287
00:14:13,093 --> 00:14:15,855
The builders used a
remote-controlled Dolly system

288
00:14:16,683 --> 00:14:18,719
to offload these giant sections.

289
00:14:19,928 --> 00:14:22,101
Joris: So it's both
light construction,

290
00:14:22,102 --> 00:14:24,656
it's lightweight
construction time,

291
00:14:25,381 --> 00:14:26,762
which is important,

292
00:14:27,936 --> 00:14:28,591
and also the kind of
environmental concern

293
00:14:28,592 --> 00:14:31,076
that we had,

294
00:14:31,077 --> 00:14:33,009
so this is achieved

295
00:14:33,010 --> 00:14:33,942
by having this steel
structure made off-site

296
00:14:33,943 --> 00:14:35,529
and coming on site by boat.

297
00:14:36,703 --> 00:14:39,016
Hayley: The scale
of this job is immense.

298
00:14:40,120 --> 00:14:42,053
Just look at the
size of the platforms

299
00:14:43,537 --> 00:14:45,688
that are used to drive off
the sections from the barges.

300
00:14:45,712 --> 00:14:47,921
They're each
the size of a truck.

301
00:14:49,302 --> 00:14:51,422
It just seems mad that this
is the safest and quickest

302
00:14:52,167 --> 00:14:55,032
and most efficient
way of working.

303
00:14:56,550 --> 00:14:59,242
But it just illustrates that
to make a building like this,

304
00:14:59,243 --> 00:15:02,108
you really have to approach it

305
00:15:03,350 --> 00:15:05,593
from a completely
different way of thinking.

306
00:15:05,594 --> 00:15:09,252
Narrator: With the steel
mega structure in place,

307
00:15:09,253 --> 00:15:11,496
they turned their attention

308
00:15:12,739 --> 00:15:14,188
to the building's
signature glass facçade.

309
00:15:14,189 --> 00:15:16,708
Joris: We wanted a glass
volume to maximize views out,

310
00:15:18,400 --> 00:15:21,092
maximum light coming
into the office environment.

311
00:15:21,817 --> 00:15:23,577
And what we looked at

312
00:15:25,096 --> 00:15:27,040
is to create a dynamic over
the length of the facçade,

313
00:15:27,064 --> 00:15:29,790
as if this building
is in motion.

314
00:15:31,206 --> 00:15:33,286
And we did that by playing
with the faceted triangles

315
00:15:35,451 --> 00:15:39,282
that go from a flat
facçade on the south side

316
00:15:39,283 --> 00:15:41,767
to a completely faceted
pineapple structure

317
00:15:41,768 --> 00:15:43,804
on the north side.

318
00:15:44,702 --> 00:15:46,358
So this transition makes that,

319
00:15:46,359 --> 00:15:48,429
when you observe the
building from distance,

320
00:15:48,430 --> 00:15:50,630
it seems to be in constant
flux with light, with clouds,

321
00:15:50,811 --> 00:15:53,192
with sunlight playing
on the triangles.

322
00:15:53,193 --> 00:15:55,125
It seems to be a
kind of moving object

323
00:15:55,126 --> 00:15:56,886
over this static
classical building.

324
00:15:57,922 --> 00:16:00,821
Corina: The finished effect

325
00:16:01,926 --> 00:16:02,823
means the glass is
constantly changing

326
00:16:02,824 --> 00:16:04,480
as you walk around it.

327
00:16:05,861 --> 00:16:07,149
There's something of the
effect of the glittering sea

328
00:16:07,173 --> 00:16:09,969
or fishy scales.

329
00:16:12,350 --> 00:16:14,070
Narrator: The gigantic
extension was secure,

330
00:16:14,490 --> 00:16:16,665
glistening above
the old firehouse.

331
00:16:17,907 --> 00:16:19,875
But there was still no
physical connection

332
00:16:20,738 --> 00:16:23,291
between the two structures.

333
00:16:23,292 --> 00:16:24,852
How do you connect
two massive buildings

334
00:16:25,674 --> 00:16:28,434
with the least impact possible?

335
00:16:28,435 --> 00:16:30,395
They decided to use the
firehouse's old dry tower.

336
00:16:33,233 --> 00:16:36,029
Philippe: You do an
extension to a building...

337
00:16:36,926 --> 00:16:39,273
At one place or at one moment,

338
00:16:39,274 --> 00:16:41,314
the two parts have a place
where they meet together.

339
00:16:42,484 --> 00:16:46,452
What we see is

340
00:16:46,453 --> 00:16:47,764
maybe the only physical
touch between old and new

341
00:16:47,765 --> 00:16:50,699
is the dry tower.

342
00:16:51,527 --> 00:16:53,804
When we see the dry tower,

343
00:16:53,805 --> 00:16:55,323
we see a little bit of
masonry above the roof,

344
00:16:55,324 --> 00:16:57,404
and then we see the start
of a glazen elevator shaft.

345
00:17:00,191 --> 00:17:02,952
The elevator starts
in the old dry tower,

346
00:17:04,471 --> 00:17:08,405
go to the glazen shaft,

347
00:17:08,406 --> 00:17:09,959
and then enter in
the new building.

348
00:17:13,170 --> 00:17:15,724
Joris: Although
you enter the lifts

349
00:17:17,139 --> 00:17:19,179
at the bottom of the
existing building in the tower,

350
00:17:19,383 --> 00:17:22,041
the lifts take you up to the
new building and connect,

351
00:17:23,421 --> 00:17:25,541
but the structure of these
lifts is hung independently

352
00:17:25,941 --> 00:17:27,701
from the steel structure
of the new building,

353
00:17:28,944 --> 00:17:31,118
so there is, it's not actually
touching the brickwork

354
00:17:31,119 --> 00:17:32,879
of the existing tower.

355
00:17:34,087 --> 00:17:35,915
The existing brickwork
tower acts as a sleeve

356
00:17:35,916 --> 00:17:38,159
in which the steel
structure is hung

357
00:17:38,160 --> 00:17:39,988
independently
from the brickwork,

358
00:17:39,989 --> 00:17:41,819
completely loose
from each other.

359
00:17:42,647 --> 00:17:44,822
Corina: The amazing thing

360
00:17:46,065 --> 00:17:47,375
is that both of these
buildings are separate.

361
00:17:47,376 --> 00:17:48,776
Replace the bricks,
and good as new.

362
00:17:50,069 --> 00:17:52,350
Of course, that would be a
very expensive change of heart.

363
00:17:56,454 --> 00:17:58,870
Narrator: The radical new
extension was in place,

364
00:18:00,044 --> 00:18:01,942
transforming the
original fire station,

365
00:18:03,289 --> 00:18:06,118
seamlessly combining
groundbreaking architecture

366
00:18:06,119 --> 00:18:08,949
with a sense of history

367
00:18:10,365 --> 00:18:12,445
to bring a forgotten
firehouse into the 21st century.

368
00:18:13,057 --> 00:18:15,887
Joris: I think actually
that our project

369
00:18:16,992 --> 00:18:19,131
allowed this building
to be reinstated

370
00:18:19,132 --> 00:18:21,372
as an important landmark
within the antwerp urban fabric.

371
00:18:22,204 --> 00:18:24,931
There might have been
all kinds of other scenarios

372
00:18:26,243 --> 00:18:28,209
where this building would
have been demolished

373
00:18:28,210 --> 00:18:29,486
and something new
would have been built.

374
00:18:29,487 --> 00:18:31,247
I think it was very important
also for zaha herself

375
00:18:31,248 --> 00:18:33,208
to keep this existing
building, to stay with this,

376
00:18:34,251 --> 00:18:36,805
and to have a separate
layer coming over it

377
00:18:37,495 --> 00:18:40,187
to layer the city,

378
00:18:40,188 --> 00:18:42,121
instead of demolishing
and rebuilding.

379
00:18:43,501 --> 00:18:46,779
Philippe: We have
a larger building

380
00:18:46,780 --> 00:18:48,679
with a bigger capacity,

381
00:18:49,576 --> 00:18:51,681
working 500 people in it now.

382
00:18:51,682 --> 00:18:53,402
And we have also a
remarkable site now here,

383
00:18:54,167 --> 00:18:57,101
a site maybe
forgotten in the past.

384
00:18:58,171 --> 00:19:02,140
Ellie: What we have
here is a building

385
00:19:02,141 --> 00:19:03,659
that deeply
respects the original

386
00:19:04,384 --> 00:19:06,385
and gives it space.

387
00:19:06,386 --> 00:19:07,938
Yet it also reacts against it,

388
00:19:07,939 --> 00:19:09,459
with something so
crazy and outlandish.

389
00:19:10,528 --> 00:19:13,082
The overall effect is that
we have these two structures

390
00:19:13,773 --> 00:19:15,913
that exist together

391
00:19:16,776 --> 00:19:17,984
but have their own identity.

392
00:19:29,547 --> 00:19:33,447
Narrator: Deep in the heart of
New York's Manhattan island,

393
00:19:33,448 --> 00:19:35,967
one of the most prestigious
addresses in the city

394
00:19:36,692 --> 00:19:39,488
has a new resident.

395
00:19:40,282 --> 00:19:43,112
An 88-story skyscraper,

396
00:19:44,459 --> 00:19:46,459
one of the highest
residential towers in the world.

397
00:19:46,944 --> 00:19:49,774
It's classed as a "super tall."

398
00:19:51,190 --> 00:19:53,536
Corina: There's only about
146 of them in the world.

399
00:19:53,537 --> 00:19:57,264
Nehemiah mabry: It's
really become a club

400
00:19:57,265 --> 00:19:58,989
that people are
desperate to be a part of.

401
00:19:58,990 --> 00:20:00,510
Narrator: Not just
tall in the extreme,

402
00:20:00,923 --> 00:20:03,822
but at just 92 feet across,

403
00:20:03,823 --> 00:20:05,687
it's also very slim

404
00:20:06,895 --> 00:20:08,455
and vulnerable to
the city's wild winds.

405
00:20:09,000 --> 00:20:11,486
Debbie sterling: 432 park Avenue

406
00:20:12,797 --> 00:20:14,557
is 15 times higher than
the width of its base.

407
00:20:14,558 --> 00:20:17,870
Narrator: To create
luxury apartments

408
00:20:17,871 --> 00:20:20,494
with unspoiled views,

409
00:20:20,495 --> 00:20:22,495
the engineers had to do
away with internal columns.

410
00:20:23,014 --> 00:20:25,672
The project would
cost $1.25 billion

411
00:20:27,018 --> 00:20:29,780
and push skyscraper
engineering to its limits.

412
00:20:31,333 --> 00:20:34,060
This gravity-defying
wonder is 432 park Avenue.

413
00:20:39,652 --> 00:20:41,412
It's 2011,

414
00:20:42,517 --> 00:20:43,797
and on a small
plot in Manhattan,

415
00:20:44,691 --> 00:20:46,331
an ambitious plan is
being put into action

416
00:20:46,866 --> 00:20:49,627
to build a 92-foot-wide tower

417
00:20:50,732 --> 00:20:52,837
and just under
1,400 feet in the sky...

418
00:20:54,494 --> 00:20:57,186
Dimensions never seen
before in skyscraper engineering.

419
00:21:02,226 --> 00:21:04,066
Engineer hezi mena was
tasked with figuring out

420
00:21:04,884 --> 00:21:06,920
how to build this
developer's dream.

421
00:21:08,232 --> 00:21:10,683
Hezi mena: It's not a
normal typical building.

422
00:21:11,994 --> 00:21:13,994
It's very tall, small
footprint, it's very slender.

423
00:21:14,894 --> 00:21:17,690
There was a lot of challenges.

424
00:21:19,001 --> 00:21:21,001
It's a tremendous effort
put in for over five years

425
00:21:22,073 --> 00:21:24,904
from start to finish.

426
00:21:27,286 --> 00:21:29,114
Narrator: This super-tall,
super-slim design

427
00:21:29,115 --> 00:21:31,635
was difficult enough
to build as it was,

428
00:21:33,084 --> 00:21:35,365
but there was another curveball
coming the engineer's way.

429
00:21:39,470 --> 00:21:41,590
With the apartments needing
to fetch $75 million plus,

430
00:21:42,887 --> 00:21:45,683
no one wanted internal columns

431
00:21:46,857 --> 00:21:48,377
getting in the way
of luxury interiors.

432
00:21:50,032 --> 00:21:52,794
They told the engineers
to get rid of them.

433
00:21:54,174 --> 00:21:56,901
Joshua: Taking away
columns is all well and good,

434
00:21:58,109 --> 00:21:59,669
but unfortunately
they're very important

435
00:21:59,939 --> 00:22:02,389
for holding up the structure.

436
00:22:02,390 --> 00:22:03,700
If you take them away, úthen
you need an alternative way

437
00:22:03,701 --> 00:22:05,261
to carry those loads
down to the ground.

438
00:22:06,394 --> 00:22:08,434
Nehemiah: Columns are
what make a building stand up.

439
00:22:08,534 --> 00:22:10,914
You take away that
structural support,

440
00:22:10,915 --> 00:22:12,848
and...[imitates explosion]

441
00:22:13,987 --> 00:22:15,387
Narrator: With a
building this tall,

442
00:22:16,265 --> 00:22:18,025
you need a way to hold
up the weight of 88 floors.

443
00:22:18,026 --> 00:22:20,097
Normally this is done
with internal columns.

444
00:22:20,718 --> 00:22:22,996
Without them,

445
00:22:24,481 --> 00:22:25,688
they needed a way to support
this super-tall skyscraper.

446
00:22:25,689 --> 00:22:28,001
Hezi: So like a typical
20, 30-story building

447
00:22:28,830 --> 00:22:31,279
would have a central core,

448
00:22:31,280 --> 00:22:33,281
what we call the
backbone of the building.

449
00:22:33,282 --> 00:22:35,002
And that will hold wind
and the earthquakes,

450
00:22:35,630 --> 00:22:37,873
seismic, horizontal forces.

451
00:22:39,150 --> 00:22:41,118
Ellie: This is the
backbone of the building.

452
00:22:42,291 --> 00:22:43,891
It's what gives
buildings their strength.

453
00:22:46,779 --> 00:22:48,055
Narrator: For 432 park Avenue,

454
00:22:48,056 --> 00:22:50,438
at 88 stories high,

455
00:22:51,162 --> 00:22:52,543
that wasn't enough.

456
00:22:53,302 --> 00:22:55,718
The engineers decided

457
00:22:55,719 --> 00:22:57,202
to make the building's
outer shell super-strong

458
00:22:57,203 --> 00:22:59,205
to reinforce the structure.

459
00:23:02,829 --> 00:23:04,589
Hezi: This building
has a backbone,

460
00:23:04,590 --> 00:23:05,832
which is also the central core.

461
00:23:07,075 --> 00:23:08,869
But we also supplemented
the exterior columns,

462
00:23:08,870 --> 00:23:11,631
so together they are
providing the stability

463
00:23:12,356 --> 00:23:14,531
that the building needs.

464
00:23:16,567 --> 00:23:18,367
Narrator: They inserted
supersized steel rebar

465
00:23:18,707 --> 00:23:20,813
into the concrete outer shell

466
00:23:21,538 --> 00:23:23,849
for added strength.

467
00:23:23,850 --> 00:23:25,851
Corina: To make
concrete stronger,

468
00:23:25,852 --> 00:23:27,991
you put steel
reinforcement into it.

469
00:23:27,992 --> 00:23:30,192
Ellie: And in this case,
it's a gigantic piece of steel.

470
00:23:33,653 --> 00:23:35,309
Narrator: Architects Chuck
knapp and Gloria glass

471
00:23:35,310 --> 00:23:36,967
kept a section of
this super thick rebar

472
00:23:37,588 --> 00:23:41,626
as a souvenir.

473
00:23:41,627 --> 00:23:43,570
Chuck knapp: You can see
the size and the diameter.

474
00:23:43,594 --> 00:23:46,182
These are major rebar, and...

475
00:23:46,183 --> 00:23:48,011
Gloria glass: In general,

476
00:23:48,012 --> 00:23:49,634
they are this size,
you know, right?

477
00:23:49,635 --> 00:23:50,669
Chuck: The information'súon
the side of the bar normally.

478
00:23:50,670 --> 00:23:53,810
Not this, this is screw,

479
00:23:53,811 --> 00:23:54,949
because they need to be able
to screw these in the couplers,

480
00:23:54,950 --> 00:23:58,056
so it's a different animal.

481
00:23:58,057 --> 00:24:00,541
Um, but it's pretty big.

482
00:24:00,542 --> 00:24:01,542
And this thing's only about
an inch, inch and a half,

483
00:24:01,543 --> 00:24:03,200
and it's very, very heavy.

484
00:24:05,858 --> 00:24:07,203
Narrator: It wasn't
enough, though,

485
00:24:07,204 --> 00:24:09,550
just to have a super
strong facçade.

486
00:24:09,551 --> 00:24:11,726
Corina: It had to be tied
to the core of the building,

487
00:24:12,968 --> 00:24:14,568
that area that houses
the elevator shaft.

488
00:24:16,558 --> 00:24:20,423
Narrator: This supersized rebar

489
00:24:20,424 --> 00:24:21,744
made the outside
of the skyscraper

490
00:24:22,391 --> 00:24:24,323
incredibly strong,

491
00:24:24,324 --> 00:24:26,602
but the engineers
made it even stronger,

492
00:24:26,603 --> 00:24:29,043
connecting it with steel beams
to the concrete elevator shaft,

493
00:24:29,606 --> 00:24:32,436
which acts like a spine

494
00:24:33,472 --> 00:24:35,024
running down the
length of the building.

495
00:24:35,025 --> 00:24:36,992
The skyscraper's core
and reinforced exterior

496
00:24:38,511 --> 00:24:40,911
gave it the strength to tower
almost 1,400 feet into the air.

497
00:24:43,136 --> 00:24:46,105
But this height
made it vulnerable

498
00:24:47,002 --> 00:24:49,141
to New York's infamous winds.

499
00:24:49,142 --> 00:24:50,799
Hayley: A skyscraper
is a structure

500
00:24:51,524 --> 00:24:53,491
that people live in.

501
00:24:53,492 --> 00:24:55,182
You hang out there,
you sleep there.

502
00:24:55,183 --> 00:24:56,805
And if the architects
and engineers

503
00:24:57,841 --> 00:24:59,738
don't do anything
about the wind,

504
00:24:59,739 --> 00:25:01,139
then you're really
going to feel it,

505
00:25:01,741 --> 00:25:03,984
especially if the
building's thin.

506
00:25:03,985 --> 00:25:06,643
Ellie: All structures
that we build move,

507
00:25:07,367 --> 00:25:08,783
but in tall structures,

508
00:25:10,232 --> 00:25:11,923
they're particularly prone
to being moved by the wind,

509
00:25:11,924 --> 00:25:14,281
and the thinner the structure,
the more vulnerable they are.

510
00:25:14,305 --> 00:25:17,067
Narrator: The
skyscraper was vulnerable

511
00:25:18,171 --> 00:25:19,965
to turbulence
created by the wind.

512
00:25:19,966 --> 00:25:23,210
If the wind was strong enough,

513
00:25:23,211 --> 00:25:24,729
it could make the
building shake,

514
00:25:24,730 --> 00:25:26,870
making it uninhabitable

515
00:25:27,940 --> 00:25:29,540
and even risking
damage to the structure.

516
00:25:33,152 --> 00:25:34,635
Joshua: When you have
a tall, thin structure like this

517
00:25:34,636 --> 00:25:36,535
and when the wind strikes it,

518
00:25:37,881 --> 00:25:39,260
the wind then wants to
pass around the building,

519
00:25:39,261 --> 00:25:41,159
creating turbulence
on the back side.

520
00:25:41,160 --> 00:25:43,160
That turbulence creates
vortices and swirls of wind

521
00:25:43,300 --> 00:25:46,233
which pass up the full
height of the building,

522
00:25:46,234 --> 00:25:47,821
and the turbulence
creates the swirls

523
00:25:47,822 --> 00:25:50,306
to first be on one side,

524
00:25:50,307 --> 00:25:51,756
and then the other,
and then the other.

525
00:25:51,757 --> 00:25:53,585
This is called vortex
shedding, and what it does

526
00:25:53,586 --> 00:25:55,587
is it starts to actually to
buffet the building sideways

527
00:25:55,588 --> 00:25:57,228
even though you're
blowing it straight on.

528
00:25:57,728 --> 00:25:59,368
Now, any building
has a natural frequency.

529
00:25:59,972 --> 00:26:01,492
Think about pushing
a child on a swing.

530
00:26:02,353 --> 00:26:04,113
If you push the child
at the right frequency,

531
00:26:04,563 --> 00:26:05,943
the child will
start to go higher.

532
00:26:07,013 --> 00:26:08,566
Same thing
happens to a building.

533
00:26:08,567 --> 00:26:10,429
If these vortices start to form

534
00:26:10,430 --> 00:26:11,914
and push the building at the
right or the wrong frequency,

535
00:26:11,915 --> 00:26:13,995
then the vibrations will
start to get out of control.

536
00:26:16,264 --> 00:26:18,161
Narrator: The engineers
started to take out windows,

537
00:26:18,162 --> 00:26:20,613
letting the wind
rush through floors

538
00:26:22,097 --> 00:26:24,248
that contain the skyscraper's
pumps and other utilities.

539
00:26:24,272 --> 00:26:27,033
Hezi: We found that when
you make these penetrations

540
00:26:28,138 --> 00:26:29,829
in the building at
certain locations,

541
00:26:31,210 --> 00:26:33,170
it reduces the wind pressures
by about 20% to 25%.

542
00:26:35,214 --> 00:26:37,941
Hayley: Every twelfth
floor is open to the air.

543
00:26:38,804 --> 00:26:40,806
That lets the wind blow through.

544
00:26:41,427 --> 00:26:43,015
Really clever.

545
00:26:44,223 --> 00:26:45,943
But it doesn't solve
the problem completely.

546
00:26:47,985 --> 00:26:49,953
Narrator: To make
sure the skyscraper

547
00:26:51,264 --> 00:26:53,127
could survive even New
York's strongest winds,

548
00:26:53,128 --> 00:26:55,048
the engineers had another
trick up their sleeves.

549
00:26:56,338 --> 00:26:59,134
The masterstroke, the
brilliant engineering trick,

550
00:27:00,377 --> 00:27:03,035
is hidden away at the
very top of the tower,

551
00:27:03,760 --> 00:27:05,900
on the 84th floor...

552
00:27:07,453 --> 00:27:09,813
Two secret giant machines
that directly counteract the wind.

553
00:27:11,802 --> 00:27:14,633
Joshua: The wind
acting on the building

554
00:27:15,323 --> 00:27:17,220
wants to make it sway.

555
00:27:17,221 --> 00:27:18,153
To stop that happening, they've
used tuned mass dampers,

556
00:27:18,154 --> 00:27:21,121
which means a
huge lump of concrete

557
00:27:21,122 --> 00:27:22,570
high up in the building.

558
00:27:22,571 --> 00:27:24,434
It's an active system,

559
00:27:24,435 --> 00:27:25,677
which means that
when the building

560
00:27:25,678 --> 00:27:26,713
wants to sway in one direction,

561
00:27:26,714 --> 00:27:28,922
the hydraulic Jacks

562
00:27:28,923 --> 00:27:29,751
will move that lump of
concrete in the other direction,

563
00:27:29,752 --> 00:27:31,718
counteracting that force

564
00:27:31,719 --> 00:27:32,822
and hopefully
keeping the building

565
00:27:32,823 --> 00:27:34,962
not moving too much.

566
00:27:34,963 --> 00:27:36,964
Hezi: This particular building,

567
00:27:36,965 --> 00:27:39,070
we have a damper,
weighs about 1,300 tons,

568
00:27:39,071 --> 00:27:41,471
absorbing the energy of the
wind that exerts on the building.

569
00:27:43,489 --> 00:27:47,285
So it has to be fast enough

570
00:27:47,286 --> 00:27:48,926
so the occupant that
sits in the apartment

571
00:27:49,806 --> 00:27:51,446
doesn't feel the
movement of the building.

572
00:27:55,259 --> 00:27:57,295
Narrator: Which is good news

573
00:27:57,296 --> 00:27:58,952
if you've paid over $75 million

574
00:27:58,953 --> 00:28:00,506
for one of the
incredible apartments.

575
00:28:03,889 --> 00:28:07,408
Ellie: 432 is without a doubt

576
00:28:07,409 --> 00:28:08,729
a feat of world-class
engineering.

577
00:28:10,102 --> 00:28:12,863
It costs a staggering
$1.25 billion to build,

578
00:28:15,348 --> 00:28:19,317
and by my estimation,

579
00:28:19,318 --> 00:28:21,198
it's about as beautiful
as a skyscraper can get.

580
00:28:25,220 --> 00:28:27,947
Narrator: 432 park Avenue
towers above the competition,

581
00:28:31,399 --> 00:28:34,677
giving it one of the most
sought-after addresses

582
00:28:34,678 --> 00:28:36,956
in New York.

583
00:28:37,716 --> 00:28:39,475
Its best view as well,

584
00:28:39,476 --> 00:28:41,512
using clever engineering

585
00:28:42,582 --> 00:28:43,982
to take skyscrapers
to their limits.

586
00:28:47,967 --> 00:28:49,520
On the rugged east
coast of Scotland,

587
00:28:50,798 --> 00:28:52,627
a ship-building
powerhouse had fallen quiet.

588
00:28:54,180 --> 00:28:57,080
But all of that was
about to change,

589
00:28:58,288 --> 00:28:59,848
thanks to one
extraordinary structure...

590
00:29:00,704 --> 00:29:03,776
The brainchild

591
00:29:05,019 --> 00:29:06,819
of one of the world's
most radical architects.

592
00:29:08,747 --> 00:29:11,196
The Victoria and Albert
museum in dundee

593
00:29:11,197 --> 00:29:13,993
rises from the river tay,

594
00:29:14,822 --> 00:29:16,099
forming a man-made cliff.

595
00:29:17,479 --> 00:29:21,172
This revolutionary design

596
00:29:21,173 --> 00:29:22,760
forced engineers to
construct a huge dam

597
00:29:22,761 --> 00:29:26,315
in the middle of
a raging river...

598
00:29:26,316 --> 00:29:29,077
Build a gravity-defying
86,000-square-foot shell

599
00:29:30,527 --> 00:29:34,219
in one piece of concrete,

600
00:29:34,220 --> 00:29:35,601
without a column in sight...

601
00:29:36,844 --> 00:29:38,569
And hang 3-ton slabs
off impossible walls.

602
00:29:40,433 --> 00:29:44,505
Ellie: It looks like the
forces of this building

603
00:29:44,506 --> 00:29:45,906
should just
completely rip it apart.

604
00:29:47,889 --> 00:29:49,289
Narrator: So, how
did they build it?

605
00:29:50,202 --> 00:29:52,963
In dundee, Scotland,

606
00:29:54,309 --> 00:29:56,552
the city's industrial
heart needed a kickstart.

607
00:29:56,553 --> 00:29:59,073
The radical plan was to build
Scotland's first design museum

608
00:30:00,315 --> 00:30:03,111
in the historic shipyards,

609
00:30:04,492 --> 00:30:06,435
where Scott's and shackleton's
legendary antarctic ship

610
00:30:06,459 --> 00:30:10,738
had been built.

611
00:30:10,739 --> 00:30:11,981
Phillip long: It's been very
important in this project

612
00:30:11,982 --> 00:30:13,466
to have a remarkable building.

613
00:30:14,329 --> 00:30:16,054
This is a new design museum,

614
00:30:16,055 --> 00:30:18,015
so it seemed right to look
for an ambitious design

615
00:30:18,299 --> 00:30:20,473
that would inspire people
to come and see the building,

616
00:30:21,785 --> 00:30:24,442
a building by an
architect who is so brilliant

617
00:30:24,443 --> 00:30:25,858
at responding to
a particular place,

618
00:30:27,239 --> 00:30:29,359
about the relationship
between the river and the city.

619
00:30:30,863 --> 00:30:33,590
Narrator: Visionary Japanese
architect kengo kuma

620
00:30:34,729 --> 00:30:36,835
designed this
brutalist masterpiece.

621
00:30:38,008 --> 00:30:40,700
He used Scotland's
stunning landscape

622
00:30:41,287 --> 00:30:43,048
for inspiration.

623
00:31:08,763 --> 00:31:11,559
Narrator: The plan...

624
00:31:12,940 --> 00:31:14,112
To lay the foundations in
the middle of the tay river,

625
00:31:14,113 --> 00:31:16,564
while battling the
Scottish weather

626
00:31:17,427 --> 00:31:18,738
and protecting local wildlife...

627
00:31:20,257 --> 00:31:23,053
To cast a giant concrete shell

628
00:31:24,468 --> 00:31:26,446
that uses nothing but its
own strangely shaped walls

629
00:31:26,470 --> 00:31:29,956
for support...

630
00:31:29,957 --> 00:31:32,441
And hang the signature cladding,

631
00:31:32,442 --> 00:31:34,961
with pieces
weighing up to 3 tons

632
00:31:34,962 --> 00:31:36,584
from the gravity-defying walls.

633
00:31:38,034 --> 00:31:40,795
Their first task was
to lay the foundations,

634
00:31:41,830 --> 00:31:44,592
but this wasn't
going to be easy.

635
00:31:46,007 --> 00:31:48,047
The design called for a
huge portion of the building

636
00:31:48,458 --> 00:31:50,667
to stick out into the tay.

637
00:31:52,151 --> 00:31:54,391
@corina: There are serious
issues with building in water.

638
00:31:55,258 --> 00:31:58,019
Debbie: Building in
water is incredibly difficult.

639
00:31:59,089 --> 00:32:01,849
You've got to hold
back an entire river

640
00:32:01,850 --> 00:32:04,231
while you're building.

641
00:32:04,232 --> 00:32:05,632
Narrator: How do
you lay foundations

642
00:32:06,338 --> 00:32:07,959
in the middle of a river?

643
00:32:07,960 --> 00:32:09,720
Structural engineer Dan clipson

644
00:32:10,859 --> 00:32:13,206
had to tackle this
monumental task.

645
00:32:13,207 --> 00:32:15,761
Dan clipson:
Building in the water

646
00:32:17,280 --> 00:32:18,418
isn't fundamentally different
from building on the ground.

647
00:32:18,419 --> 00:32:19,765
@the foundations of the building

648
00:32:20,869 --> 00:32:21,939
still need to go
down to bedrock.

649
00:32:21,940 --> 00:32:23,664
So whether it's in the river

650
00:32:23,665 --> 00:32:25,011
or on the land
behind the river wall,

651
00:32:25,012 --> 00:32:26,253
we're still piling down
20 meters into the rock

652
00:32:26,254 --> 00:32:27,894
to get a good foundation
for the building.

653
00:32:29,119 --> 00:32:31,079
Dundee is a very nice
sunny city most of the time.

654
00:32:31,259 --> 00:32:33,259
It's also cold and wet in
winter, like many places.

655
00:32:34,538 --> 00:32:36,658
So the weather plays quite
a key part in construction.

656
00:32:37,472 --> 00:32:39,509
We're working by a tidal river,

657
00:32:41,028 --> 00:32:41,787
working in a climate that has
extreme colds during the winter

658
00:32:41,788 --> 00:32:44,824
and rain and wind.

659
00:32:46,205 --> 00:32:48,205
They all need to be
considered during construction.

660
00:32:48,759 --> 00:32:50,359
Narrator: They had
to lay the foundations

661
00:32:50,727 --> 00:32:52,590
on a seriously difficult site.

662
00:32:52,591 --> 00:32:56,249
To make it possible,

663
00:32:56,250 --> 00:32:57,871
they decided to build a dam

664
00:32:57,872 --> 00:32:59,352
out of 12,500 tons
of stone and earth,

665
00:32:59,805 --> 00:33:02,911
called a cofferdam.

666
00:33:03,947 --> 00:33:05,948
Corina: A cofferdam
is an enclosure

667
00:33:05,949 --> 00:33:08,054
built within a body of water

668
00:33:08,055 --> 00:33:09,883
to allow the enclosed
area to be pumped out.

669
00:33:09,884 --> 00:33:11,924
Ellie: That means that you
can get on with your work

670
00:33:12,714 --> 00:33:14,682
in a nice dry environment.

671
00:33:15,890 --> 00:33:17,730
Narrator: The cofferdam
would let the engineers

672
00:33:18,617 --> 00:33:20,480
extend the existing dockside,

673
00:33:20,481 --> 00:33:23,448
pushing the site into the tay.

674
00:33:23,449 --> 00:33:25,900
Building the dam was
a race against time.

675
00:33:27,281 --> 00:33:29,766
Phillip: There are
protected species in the river,

676
00:33:30,629 --> 00:33:32,768
particularly a species of seal,

677
00:33:32,769 --> 00:33:34,598
and so we had a
very short time-scale

678
00:33:36,083 --> 00:33:38,483
that would allow us to build
our foundation out in the river.

679
00:33:38,637 --> 00:33:42,122
We went on site
in march in 2015,

680
00:33:42,123 --> 00:33:43,987
and we had to make sure

681
00:33:45,368 --> 00:33:46,575
that all of that work that
was done out in the river

682
00:33:46,576 --> 00:33:47,896
was done by the
beginning of June,

683
00:33:48,819 --> 00:33:50,419
the beginning of the
seal pupping season.

684
00:33:51,132 --> 00:33:53,893
Narrator: The local
grey seal population

685
00:33:54,618 --> 00:33:57,482
lives close to the site.

686
00:33:57,483 --> 00:33:58,725
Their breeding season
was just around the corner,

687
00:33:58,726 --> 00:34:01,591
and the second it started,

688
00:34:02,833 --> 00:34:04,433
all work in the river
would have to stop.

689
00:34:06,423 --> 00:34:09,391
The construction team

690
00:34:09,392 --> 00:34:10,737
hammered massive
steel slats into the riverbed,

691
00:34:10,738 --> 00:34:12,912
filling in the
centre with rubble

692
00:34:14,121 --> 00:34:15,466
to hold back the
force of the tay river.

693
00:34:15,467 --> 00:34:18,056
Dan: What was done in this case

694
00:34:19,229 --> 00:34:20,816
was a temporary bit
of land was created,

695
00:34:20,817 --> 00:34:22,197
so the contractor installed
a piled wall out into the river

696
00:34:22,198 --> 00:34:24,062
and filled it in with ground

697
00:34:24,890 --> 00:34:26,718
to create a new bit of land

698
00:34:26,719 --> 00:34:28,168
that we could then
build the building on.

699
00:34:28,169 --> 00:34:28,825
We were constructing
the building

700
00:34:28,826 --> 00:34:30,791
on top of solid ground,

701
00:34:30,792 --> 00:34:32,345
even though it
was above the river.

702
00:34:32,346 --> 00:34:34,554
Narrator: The engineers
drilled down 65 feet,

703
00:34:34,555 --> 00:34:36,419
anchoring the
building's foundations

704
00:34:37,489 --> 00:34:39,077
to the rock bed
on concrete piles.

705
00:34:39,767 --> 00:34:43,839
At the same time,

706
00:34:43,840 --> 00:34:44,978
they would have to make
sure the corrosive salt of the tay

707
00:34:44,979 --> 00:34:46,601
wouldn't eat away
the foundations.

708
00:34:47,982 --> 00:34:50,102
They decided to use a
concrete with a special formula,

709
00:34:51,192 --> 00:34:54,057
specifically
designed to resist salt.

710
00:34:55,438 --> 00:34:58,819
Dan: Salt and chlorides are
the enemy of our structure.

711
00:34:58,820 --> 00:35:01,789
So they cause corrosion

712
00:35:02,928 --> 00:35:03,722
and damage to the
building over time

713
00:35:03,723 --> 00:35:05,792
that we have to prevent.

714
00:35:05,793 --> 00:35:06,621
The concrete mixes
we've used in this building

715
00:35:06,622 --> 00:35:08,967
had to be different.

716
00:35:08,968 --> 00:35:10,037
We had to change them
from what we'd normally do

717
00:35:10,038 --> 00:35:11,280
in order to make
them more resistant

718
00:35:11,281 --> 00:35:13,420
to the elements, to the salts,

719
00:35:13,421 --> 00:35:14,628
to all of the things that are
trying to attack the building.

720
00:35:14,629 --> 00:35:17,528
Narrator: The
foundations were secure,

721
00:35:17,529 --> 00:35:19,185
and a new piece of land had
been built into the tay river,

722
00:35:19,186 --> 00:35:23,603
ready for the next
step of the build.

723
00:35:23,604 --> 00:35:26,004
The engineers now had to
tackle the building's radical shape.

724
00:35:28,091 --> 00:35:30,887
They wanted the walls to
support the entire structure,

725
00:35:32,475 --> 00:35:35,202
removing any interior columns
from the gallery spaces.

726
00:35:37,480 --> 00:35:41,241
But the leaning
and twisting design

727
00:35:41,242 --> 00:35:42,642
threatened to tear
the museum apart.

728
00:35:43,900 --> 00:35:46,592
Hayley: Normally you
would never build walls

729
00:35:47,421 --> 00:35:49,387
that are sloping outwards,

730
00:35:49,388 --> 00:35:52,287
and that's because,

731
00:35:52,288 --> 00:35:53,564
as well as the usual
gravitational forces

732
00:35:53,565 --> 00:35:55,566
that are pushing
down on the building,

733
00:35:55,567 --> 00:35:57,533
you're adding an
extra layer of strain

734
00:35:57,534 --> 00:36:00,260
as the walls are
being pulled apart.

735
00:36:00,261 --> 00:36:03,850
Joshua: The shape
of this building is,

736
00:36:03,851 --> 00:36:05,990
it's really incredible

737
00:36:05,991 --> 00:36:06,612
@and something that
you don't see in architecture

738
00:36:06,613 --> 00:36:08,441
very often for a reason,

739
00:36:08,442 --> 00:36:10,236
@and that's
because it just takes

740
00:36:10,237 --> 00:36:11,478
a lot of expertise,
science, and maths

741
00:36:11,479 --> 00:36:13,308
to achieve what
they've achieved here.

742
00:36:13,309 --> 00:36:15,689
Narrator: To get
the calculations right,

743
00:36:15,690 --> 00:36:17,530
they used the very latest
3D computer modelling

744
00:36:17,589 --> 00:36:21,695
and sculptural techniques.

745
00:36:21,696 --> 00:36:23,776
Dan: This is a building
that is a very modern design.

746
00:36:24,009 --> 00:36:25,906
We needed to use a lot
of computational power

747
00:36:25,907 --> 00:36:27,387
to create the design
of this building.

748
00:36:28,358 --> 00:36:30,256
We looked at the shape
at the concept stage,

749
00:36:30,257 --> 00:36:32,396
and we could have
put a frame in here

750
00:36:32,397 --> 00:36:34,077
and hung the facçade
off the outside of it.

751
00:36:34,709 --> 00:36:35,813
It could have been
a traditional building.

752
00:36:35,814 --> 00:36:38,333
The problem with that is

753
00:36:38,334 --> 00:36:39,403
we'd fill the building
with a lot of stuff,

754
00:36:39,404 --> 00:36:41,267
and this is a museum,

755
00:36:41,268 --> 00:36:42,613
this is an art space,
this is a gallery,

756
00:36:42,614 --> 00:36:44,580
this is a place for
people to come and enjoy

757
00:36:44,581 --> 00:36:46,168
that we didn't want to fill
with bits of steel and concrete.

758
00:36:46,169 --> 00:36:48,482
Historically we'd
build buildings

759
00:36:49,621 --> 00:36:51,061
with the walls
carrying the weight...

760
00:36:51,726 --> 00:36:53,382
Stone huts back
in the dark ages.

761
00:36:53,383 --> 00:36:54,764
The walls carried the roof,

762
00:36:56,283 --> 00:36:57,835
and that was how we protected
you from the wind and the rain.

763
00:36:57,836 --> 00:36:58,664
So we took the option of
using the shell of the building

764
00:36:58,665 --> 00:37:00,666
as its structure,

765
00:37:02,081 --> 00:37:03,496
kind of going back to the
old way of doing things...

766
00:37:03,497 --> 00:37:05,118
Make the outside of the
building hold the building up,

767
00:37:05,119 --> 00:37:07,016
and then you don't need
to put anything inside.

768
00:37:07,017 --> 00:37:08,657
Because of the way
the building is pulling

769
00:37:09,123 --> 00:37:11,400
on all the different
bits of itself...

770
00:37:11,401 --> 00:37:12,608
The roof pulls on the walls,
the walls pull on the roof...

771
00:37:12,609 --> 00:37:14,089
We had to design
it as one big object.

772
00:37:14,956 --> 00:37:18,476
Narrator: To make the
most of the exhibition spaces,

773
00:37:18,477 --> 00:37:20,317
the architect didn't want
any interior columns.

774
00:37:21,308 --> 00:37:24,034
To achieve this, the
shell of the building,

775
00:37:24,759 --> 00:37:26,727
the exterior walls,

776
00:37:27,797 --> 00:37:29,936
had to support the
roof and themselves.

777
00:37:29,937 --> 00:37:32,698
No easy task, given
their extreme shapes.

778
00:37:34,873 --> 00:37:37,634
The solution was to design
the shell to work as one piece,

779
00:37:38,911 --> 00:37:41,638
using its own weight
and steel reinforcements

780
00:37:42,536 --> 00:37:45,228
to hold the building together.

781
00:37:46,160 --> 00:37:49,025
But there was a problem.

782
00:37:50,198 --> 00:37:52,130
The shell would be
only structurally sound

783
00:37:52,131 --> 00:37:53,926
when the last
piece was in place.

784
00:37:55,134 --> 00:37:56,854
Until then, the whole
building was unstable.

785
00:37:58,448 --> 00:38:02,348
Joshua: So the leaning
walls and the whole building

786
00:38:02,349 --> 00:38:03,970
is really held together
by these tension forces

787
00:38:03,971 --> 00:38:05,931
pulling everything back
towards that central core.

788
00:38:06,491 --> 00:38:09,872
Dan: The skin of
the building itself

789
00:38:09,873 --> 00:38:12,012
is doing all the work.

790
00:38:12,013 --> 00:38:13,324
It's carrying the
weight of the building,

791
00:38:13,325 --> 00:38:14,601
it's pushing and pulling
with different forces,

792
00:38:14,602 --> 00:38:16,293
it's resisting the
wind and the rain,

793
00:38:16,294 --> 00:38:18,536
it's keeping the
building watertight,

794
00:38:18,537 --> 00:38:19,744
holding the facçade up and
the cladding on the outside.

795
00:38:19,745 --> 00:38:22,437
But it's primarily
supporting the building.

796
00:38:22,438 --> 00:38:24,509
Narrator: They used their
advanced computer model

797
00:38:25,544 --> 00:38:27,097
to make the walls
super-efficient,

798
00:38:28,582 --> 00:38:30,982
making them as thin as possible,
and more importantly, light.

799
00:38:31,999 --> 00:38:34,726
Dan: That resulted
in some of the walls

800
00:38:35,451 --> 00:38:37,486
being half as thick.

801
00:38:37,487 --> 00:38:39,005
They went from 600 millimetres
down to 300 millimetres,

802
00:38:39,006 --> 00:38:40,765
which is a significant
saving in materials

803
00:38:40,766 --> 00:38:42,974
and reduces the
weight of the building,

804
00:38:42,975 --> 00:38:45,356
the size of the foundations.

805
00:38:45,357 --> 00:38:46,771
It's a lot of positive
outcomes from that.

806
00:38:46,772 --> 00:38:48,567
Narrator: Now they
faced the challenge

807
00:38:49,775 --> 00:38:51,335
of building the
81,000-cubic-foot shell.

808
00:38:52,916 --> 00:38:55,678
This would only be stable

809
00:38:56,955 --> 00:38:58,818
when the last pour of
concrete had hardened.

810
00:38:58,819 --> 00:39:01,442
It wouldn't be able to
support its own weight

811
00:39:02,167 --> 00:39:05,307
until the very end.

812
00:39:05,308 --> 00:39:07,068
Dan: Because of the
shell we had to make,

813
00:39:08,173 --> 00:39:09,207
it was like casting
a giant mold.

814
00:39:09,208 --> 00:39:11,417
We had to finish the casting

815
00:39:11,418 --> 00:39:12,625
before we could
take the mold away,

816
00:39:12,626 --> 00:39:13,936
'cause in a partially
completed state,

817
00:39:13,937 --> 00:39:16,145
the building isn't stable.

818
00:39:16,146 --> 00:39:18,320
Narrator: As the
shell started to go up,

819
00:39:18,321 --> 00:39:20,241
the builders had to add
more and more formwork...

820
00:39:20,806 --> 00:39:24,464
The molds that
hold the concrete...

821
00:39:24,465 --> 00:39:25,865
To support the
precarious structure.

822
00:39:26,674 --> 00:39:29,400
If they removed
a piece too early,

823
00:39:29,401 --> 00:39:30,761
the whole structure
would collapse.

824
00:39:31,748 --> 00:39:33,440
After a year and a
half of constant work,

825
00:39:34,579 --> 00:39:36,443
the last concrete
pour was completed.

826
00:39:37,513 --> 00:39:39,480
It was time to take
off the formwork

827
00:39:40,688 --> 00:39:42,408
and see if all the
calculations were correct

828
00:39:43,173 --> 00:39:45,293
and if this one-of-a-kind
design would support itself.

829
00:39:47,799 --> 00:39:50,733
Phillip: Finally,

830
00:39:51,975 --> 00:39:52,666
after nearly two years
of it coming into place,

831
00:39:52,667 --> 00:39:54,564
it came down,

832
00:39:55,634 --> 00:39:56,428
and it was a very,
very exciting moment

833
00:39:56,429 --> 00:39:58,187
to see that formwork removed

834
00:39:58,188 --> 00:40:00,052
and the shell of vanda dundee

835
00:40:00,915 --> 00:40:02,538
finally born, finally revealed.

836
00:40:05,299 --> 00:40:06,779
Narrator: When the
molds were removed,

837
00:40:07,957 --> 00:40:09,637
the black concrete
underneath was revealed.

838
00:40:10,235 --> 00:40:12,479
It was colourized
with a pfa paint,

839
00:40:13,203 --> 00:40:15,689
or pulverized fuel ash,

840
00:40:17,069 --> 00:40:18,989
made from the waste of
coal-fired power stations.

841
00:40:19,071 --> 00:40:21,936
At last,

842
00:40:23,213 --> 00:40:24,766
the vanda's groundbreaking
shell was complete.

843
00:40:24,767 --> 00:40:26,967
But architect kengo kuma
wasn't going to leave it there.

844
00:40:27,977 --> 00:40:30,980
He had big plans for the finish.

845
00:40:41,784 --> 00:40:44,476
Narrator: He wanted to
use giant concrete blocks

846
00:40:45,995 --> 00:40:48,276
to mimic the craggy appearance
of Scottish coastal cliffs.

847
00:40:50,171 --> 00:40:52,933
But it turns out, creating
a random natural pattern

848
00:40:53,899 --> 00:40:56,730
is harder than you think.

849
00:40:59,836 --> 00:41:01,716
Dan: If you look at the
facçade of the building,

850
00:41:02,736 --> 00:41:04,909
at the external
panels from outside,

851
00:41:04,910 --> 00:41:06,428
you'll see that they all
look slightly different.

852
00:41:06,429 --> 00:41:08,810
There's a random
pattern to them.

853
00:41:08,811 --> 00:41:10,328
They step in and out,
they step up and down,

854
00:41:10,329 --> 00:41:12,021
they kind of weave around

855
00:41:13,401 --> 00:41:14,333
and create this sort of
vision of this cliff face,

856
00:41:14,334 --> 00:41:15,818
of this random assortment.

857
00:41:16,888 --> 00:41:18,544
In reality, they're
not that random.

858
00:41:18,545 --> 00:41:20,625
If we did an entirely random
pattern for the facçade,

859
00:41:20,926 --> 00:41:22,514
if every plank
was just generated

860
00:41:23,411 --> 00:41:25,516
by some mathematical formula,

861
00:41:25,517 --> 00:41:26,345
the risk is that two or three
planks next to each other

862
00:41:26,346 --> 00:41:27,726
would look similar enough

863
00:41:29,003 --> 00:41:30,210
that your brain would
see them as the same,

864
00:41:30,211 --> 00:41:31,660
so we had to
create this algorithm

865
00:41:31,661 --> 00:41:33,386
that allowed us
to fine-tune things

866
00:41:33,387 --> 00:41:34,733
to make sure the architects

867
00:41:35,907 --> 00:41:37,355
could look at the
building from every angle

868
00:41:37,356 --> 00:41:39,334
and they could tweak and
adjust until it looked just so.

869
00:41:39,358 --> 00:41:42,844
Narrator: With the shell
working as one piece,

870
00:41:42,845 --> 00:41:44,743
it was ready to take

871
00:41:45,779 --> 00:41:47,918
the massive weight
of the cladding.

872
00:41:47,919 --> 00:41:50,119
All in all, there are 2,500
pre-cast rough stone panels,

873
00:41:50,680 --> 00:41:53,511
weighing up to 6,600 pounds each

874
00:41:54,581 --> 00:41:58,584
and spanning up to 13 feet.

875
00:41:58,585 --> 00:42:00,207
Hanging them was
going to be a challenge.

876
00:42:01,588 --> 00:42:04,522
Dan: The facçade panels

877
00:42:06,006 --> 00:42:06,834
are made from a concrete
and reconstituted stone material.

878
00:42:06,835 --> 00:42:08,871
They weigh an awful lot.

879
00:42:09,665 --> 00:42:11,735
The facçade, the panels

880
00:42:11,736 --> 00:42:13,219
weigh about the same as
the wall that's holding them up.

881
00:42:13,220 --> 00:42:15,117
The panels on a more
vertical wall are smaller,

882
00:42:15,118 --> 00:42:16,429
panels on the more
sloping walls are bigger.

883
00:42:16,430 --> 00:42:18,087
That presents another challenge

884
00:42:19,398 --> 00:42:20,398
because the walls that
are sloping and twisting

885
00:42:20,399 --> 00:42:22,849
are working harder,

886
00:42:22,850 --> 00:42:24,264
and the cladding hung
off them is heavier.

887
00:42:24,265 --> 00:42:25,507
So it's a sort of double
whammy of challenge

888
00:42:25,508 --> 00:42:27,647
that we had to
overcome in the design.

889
00:42:27,648 --> 00:42:29,315
Narrator: The anchoring
points of the giant stone cladding

890
00:42:29,339 --> 00:42:32,721
had to be seriously heavy-duty.

891
00:42:32,722 --> 00:42:34,690
The engineers decided
to set them in the shell

892
00:42:35,553 --> 00:42:37,762
when it was first being poured,

893
00:42:38,970 --> 00:42:40,764
letting the outer shell
harden around them.

894
00:42:40,765 --> 00:42:43,491
This, though, left
no room for error.

895
00:42:44,941 --> 00:42:47,181
Get it wrong, and the
cladding wouldn't fit on the shell.

896
00:42:48,289 --> 00:42:51,982
In the end, every
anchor except three

897
00:42:51,983 --> 00:42:54,226
was in the perfect position.

898
00:42:57,644 --> 00:43:00,025
The exterior of the
building was complete,

899
00:43:01,130 --> 00:43:03,477
a testament to the
Scottish landscape.

900
00:43:05,341 --> 00:43:09,482
Vanda dundee is proof
that radical engineering

901
00:43:09,483 --> 00:43:13,624
can breathe new life
into a long-neglected area,

902
00:43:13,625 --> 00:43:16,214
using the natural environment
to redefine the urban landscape.

903
00:43:19,804 --> 00:43:22,600
Hayley: The end result
is a beautiful building

904
00:43:23,428 --> 00:43:27,189
that is truly built to last,

905
00:43:27,190 --> 00:43:29,675
as tough and rugged
and as beautiful

906
00:43:29,676 --> 00:43:33,886
as the Scottish
landscape that inspired it.

907
00:43:33,887 --> 00:43:36,247
Phillip: Dundee's falling in
love with its waterfront again,

908
00:43:37,200 --> 00:43:39,478
and people that come
to experience vanda dundee

909
00:43:40,687 --> 00:43:42,827
now have a new
relationship with the river,

910
00:43:44,242 --> 00:43:46,242
which has been suchúan
important part of this city.

911
00:43:46,969 --> 00:43:48,769
Narrator: Extraordinary
engineering challenges

912
00:43:50,110 --> 00:43:52,070
had been overcome to
create the designer's vision.

913
00:43:53,147 --> 00:43:55,874
Dan: I consider this to
be a landmark project.

914
00:43:56,634 --> 00:43:59,463
I find it fascinating

915
00:43:59,464 --> 00:44:00,913
that people look at it
as a piece of engineering

916
00:44:00,914 --> 00:44:03,122
as well as a piece of
art and architecture.

917
00:44:03,123 --> 00:44:04,963
It's a visible piece of
structural engineering.


