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[Jay] How do you make a
1.2 million-square-foot
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conference center
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that's as welcoming to wildlife
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as it is to people?
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To attempt a green roof
on this scale
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was a huge undertaking,
a huge risk.
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[Jay] How do you build
a beautiful bridge
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that can also rise
160 feet in the air?
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You can move the bridge
with one hand, huh, you know?
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It's, uh...it's crazy.
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[Jay] And how do you
construct a 668-foot-tall,
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cocoon-shaped tower
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in an earthquake zone?
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You've gotta make sure that
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your beautifully
designed building
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doesn't essentially
rip itself apart.
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[music]
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[Jay] This is the age
of the extraordinary.
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[Dr. Agbedor]
It's totally different
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from anything around it.
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It's like a visitor
from another planet.
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[Jay] Where ingenious
engineers have unleashed
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unchecked creativity.
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Now their secrets are revealed
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as we discover
the amazing stories
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of their construction.
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[Dr. Mabry]
It is simply mindblowing.
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I mean, how do you come up with
an idea like that?
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[Jay] To try and understand...
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...how did they build that.
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Next time
you're up in Vancouver,
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I recommend you check out
the greenest convention center
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in Canada.
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It has a 6-acre living roof
with 400,000 plants
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and a lawn which takes
six gardeners two weeks to mow.
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Since opening back in 2009,
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there's been a real buzz
around this building.
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That'll probably be the
quarter of a million honeybees
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who call it home.
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Vancouver, British Columbia
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sits over a series of islands
on the edge of the Pacific.
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Since the millennium,
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the city has been
restoring this coastline
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and bringing back
its biodiversity.
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So, how do you build a huge
new waterfront convention center
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that will have a positive
impact on this landscape?
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We have to feel responsible
for what happens on this site.
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It's gonna impact
the whole waterfront.
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[Jay] The answer is
this extraordinary,
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eco-friendly structure
that straddles the shore
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and the ocean.
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Constructing anything on water
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is way more difficult
than building on land.
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[Jay] Creating
wildlife-friendly areas
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below the waterline
and above it.
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[Corina]
Six acres of living landscape.
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Just imagine how much weight
that's adding to the roof.
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[Jay] All wrapped up
in a spectacular, asymmetrical,
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1.2 million-square-foot
building.
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There isn't really
a precedent in Canada
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for a building,
a structure of this size.
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[Jay] This is Vancouver
Convention Centre West.
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So, how did they build it?
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[music]
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[Jay] It's the early 2000s.
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LMN Architects
have been given the job
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of designing a new
convention center for Vancouver
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over three times
the size of its predecessor.
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This is one of
the biggest projects
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we've ever designed.
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We have to push the envelope.
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[Jay] An 11-acre waterfront
site is chosen by the city.
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But the plot isn't
big enough for what they need.
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We were wanting
to keep it intimate,
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but we needed
the square footage as well.
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So we needed to build
at least 40% of it over water.
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[Jay] As if that
wasn't challenging enough,
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the city also wants the team
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to rejuvenate
this part of the coast.
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Known as Coal Harbour,
it's a former industrial site
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which has undergone
gradual redevelopment.
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This site was
the last remaining piece
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of the downtown waterfront
that had not been restored.
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[music]
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[Jay] The team needs to
create an epic new building
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for the city
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that will leave this
part of the shoreline
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in a better state
than they found it.
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First, they'll have to find
a way to fit a building
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bigger than the plot
onto the waterfront site.
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This will mean
building out into the bay
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on a specially designed platform
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which is strong enough
to support the building.
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They'll need to figure out
how to squeeze
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a massive event space
and enough parking
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into the striking structure
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with its views across the water.
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But what will make
this building really special
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will be the way
it helps the local environment.
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Under the waterline,
they need to design and build
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a pioneering habitat
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to encourage
local wildlife to return.
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And the whole center will
need to support a green roof
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the size of six American
football fields.
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[music]
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[Jay] It's 2003.
Design work is underway,
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and the first curveball comes
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when Vancouver
is chosen to host
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the 2010 Winter Olympics.
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There was a decision
that the convention center
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should serve the Olympics
as the press center.
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[Jay] The building will
play host to reporters
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from over 80 countries.
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It's an honor,
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but it sets off
a seven-year ticking clock.
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So that may seem
like a long time,
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but in building development,
that's a pretty short order.
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[music]
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[Jay] Time is of the essence.
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So before they even finish
designing the building,
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they start constructing
a solid base
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called a marine deck.
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The typical foundation
for marine decks
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like the one used here
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includes driving piles
into the seabed
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and topping them with pile caps.
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These are large concrete blocks
that evenly distribute the load,
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creating a foundation
stable enough for construction.
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[Jay] For this building,
they will need
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a 1000-foot-long deck.
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That means driving 900 piles
200 feet down
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until they reach the bedrock.
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With the Olympics approaching,
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maintaining the necessary pace
requires military efficiency.
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The marine deck was built
from the east towards the west
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and was in a kind of
assembly line-type process,
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where pile driving
was started in one end,
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and then was--
pile caps were started
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while the pile driving
was moving further west.
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[Jay] With the piles in,
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the concrete deck
takes shape on top.
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It's a huge job,
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but after two years,
20,000 tons of steel,
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and 34,000 cubic yards
of concrete,
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finally they have a base
for a new conference center.
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[music]
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[Jay] The next challenge
is to engineer the structure.
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The architects want
big, open spaces inside
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and huge sloping glass windows
on the outside,
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and an enormous
green roof on top.
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Coming up with a structure
that's strong enough
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to achieve all of this
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is extremely complicated
to get right.
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You don't really see
the complexity of it
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until you see it
in 3D and 3D modeling.
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Nothing comes together square.
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Everything's got an angle,
a two-directional angle, slopes.
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[music]
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[Jay] The team
opts for a steel frame,
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which will handle
these challenges
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better than concrete.
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Steel is the perfect material
for spanning large areas.
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It's strong. It's durable.
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It's relatively light
compared to concrete
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and doesn't need
nearly as much maintenance.
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[Jay] But in engineering terms,
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what is considered light
is relative.
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Some of the pieces
of structural steel
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weigh 730 pounds per foot.
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[Robert] These trusses would be
delivered to the project site
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on very large trucks
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and then have to be
hoisted into place
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with very large cranes
on the marine deck.
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So the marine deck
had to include capacity
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for these large cranes
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to be able to literally
build the building on top of it.
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[Jay] The next challenge
the engineers face
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is making sure the building
will be strong enough.
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Vancouver is a high seismic zone
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with large earthquakes
that happen
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every 300 to 500 years.
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And the next
big earthquake is expected
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in the next hundred years.
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[Jay] To ensure
the conference center
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is prepared for the threat,
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the team designs
and fits seismic braces.
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These huge springs act like
shock absorbers on a car
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if the building gets hit.
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As it sways one way or another,
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it's getting a little bit
of help out of this spring,
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increasing or decreasing in load
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as the building
sways one way or another.
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[Jay] It's a great solution
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that will allow the team
to finish the huge frame
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by June 2007,
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two and a half years
away from the Olympics.
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But before that,
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the team has to work out
a way of making the building
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a safe habitat for
an endangered local fish.
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One of the really fundamental
things that's important
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in this region
is the salmon migration.
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And the baby salmon
will swim along the shore.
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They want to be in shallow water
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so that they can
avoid predators.
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[Jay] The team has a bold idea.
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To help stem the rapid decline
in the population,
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they want to create shelter
for migrating young salmon
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and other species
in the underwater parts
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of the building.
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The daunting task
of designing it
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falls to new project
engineer Daniel Leonard.
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[Daniel] I had just
graduated from university.
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And they came to me,
uh, on my first week
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and said that they had
this really challenging aspect
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00:10:02,937 --> 00:10:05,806
of the project that
they wanted me to lead.
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[Jay] The problem is
there's no blueprint
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00:10:08,442 --> 00:10:10,310
for a structure like this.
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You're basically told,
"Please do something
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00:10:12,112 --> 00:10:13,680
"that's never been done before
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"in the shortest
amount of time possible,
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and do it on time
and on budget."
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[music]
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[Jay] In Vancouver,
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the team behind a new
waterfront conference center
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00:10:34,801 --> 00:10:36,570
is racing to
finishing it in time
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for the 2010 Winter Olympics.
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First, though,
they need to work out
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how to create
an environment around it
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that will protect the endangered
local sockeye salmon.
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Their solution is
to create a series of
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precast concrete benches
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that will mimic
the natural shoreline,
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periodically exposed
and covered up by the tide,
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with plenty of hiding places
for ocean plants and animals.
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[Daniel] The benches
were built with ridges
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and also tidal pools in them
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to provide the maximum
amount of habitat
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for the surface area
that was provided.
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The materials were chosen
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to replicate
that shoreline as well.
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Exposed aggregate concrete
to allow marine growth
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to attach to
the exposed aggregate.
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[Jay] Because these benches
will hang off the building
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and below the high tide line,
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there's no way that they
can cast the concrete in place.
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All of the leg units
and the plank units
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00:11:35,662 --> 00:11:38,665
were built at a, uh,
precast concrete factory
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on Vancouver Island,
and then they were barged over.
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And then a massive
300-ton-capacity crane
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00:11:45,172 --> 00:11:46,907
was used to pick up the legs
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and to swing them in place
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and to clip them onto
the inside of the foundation.
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And all of the legs,
all 76 of them,
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were installed in four days.
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[Jay] Scientists
will carefully monitor
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00:11:58,852 --> 00:12:01,855
the impact of the structure on
the sockeye salmon population.
257
00:12:03,390 --> 00:12:04,724
For now, though,
258
00:12:04,824 --> 00:12:06,494
with the Olympic deadline
fast approaching,
259
00:12:06,594 --> 00:12:09,496
the team turns
its attention to the roof.
260
00:12:11,965 --> 00:12:14,034
[music]
261
00:12:14,134 --> 00:12:17,237
[Jay] The ambition is
to transform all 6 acres of it
262
00:12:17,337 --> 00:12:20,541
into the largest
green roof in Canada.
263
00:12:20,641 --> 00:12:22,777
Vancouver is actually
one of the leaders
264
00:12:22,877 --> 00:12:24,745
in green roof development.
265
00:12:24,812 --> 00:12:27,715
Uh, it has a long history.
266
00:12:27,815 --> 00:12:29,316
Some of the earliest green roofs
267
00:12:29,450 --> 00:12:31,952
are just in
this neighborhood here.
268
00:12:32,052 --> 00:12:33,988
[Jay] Green roofs
look beautiful,
269
00:12:34,121 --> 00:12:37,757
cool buildings,
attract wildlife.
270
00:12:37,857 --> 00:12:41,328
But creating one this
large is unprecedented.
271
00:12:41,461 --> 00:12:44,131
[Reece] To attempt
a green roof on this scale
272
00:12:44,264 --> 00:12:47,801
was a huge, huge undertaking
and huge risk.
273
00:12:50,036 --> 00:12:51,105
[Jay] The first
problem is making sure
274
00:12:51,238 --> 00:12:53,774
the roof isn't too heavy.
275
00:12:53,874 --> 00:12:55,942
[Corina] Six acres
of living landscape.
276
00:12:56,042 --> 00:13:00,447
Just imagine how much weight
that's adding to the roof.
277
00:13:00,580 --> 00:13:02,750
[Jay] The engineers
calculate that the structure
278
00:13:02,850 --> 00:13:05,986
can take up to 6 inches
of compacted soil.
279
00:13:06,053 --> 00:13:07,287
More than that,
280
00:13:07,387 --> 00:13:10,224
and there's a risk
it could collapse.
281
00:13:10,357 --> 00:13:13,393
Work starts by adding
an even layer of gravel
282
00:13:13,494 --> 00:13:14,795
topped with soil.
283
00:13:14,895 --> 00:13:16,730
[Reece] We had
truckloads of gravel,
284
00:13:16,864 --> 00:13:18,965
truckloads of soil.
285
00:13:19,065 --> 00:13:20,634
That was all craned up.
286
00:13:20,734 --> 00:13:22,469
And then we had
conveyor belts set up
287
00:13:22,569 --> 00:13:24,337
to distribute the soil.
288
00:13:25,506 --> 00:13:26,940
[Jay] To add to the challenge,
289
00:13:27,040 --> 00:13:29,443
some sections of
the roof slope steeply.
290
00:13:29,509 --> 00:13:32,546
So the team needs to
add special stabilization mats
291
00:13:32,680 --> 00:13:36,816
with pockets to stop everything
from sliding downhill.
292
00:13:36,883 --> 00:13:40,120
Then they are ready for
the mammoth planting job.
293
00:13:40,220 --> 00:13:44,891
Six acres, 400,000 plants,
and 40,000 bulbs
294
00:13:44,991 --> 00:13:47,427
involved in planting this space.
295
00:13:49,396 --> 00:13:51,732
[Jay] All of the plants
are native to the area
296
00:13:51,832 --> 00:13:55,369
in order to make sure they
thrive on the exposed roof.
297
00:13:55,502 --> 00:13:58,905
And all of them must go
in the exact right spot.
298
00:14:00,774 --> 00:14:04,411
[Hannah] There was
this kind of grid
299
00:14:04,545 --> 00:14:07,180
that had the corresponding
colored tags.
300
00:14:07,280 --> 00:14:09,116
So let's say, you know,
the native strawberries
301
00:14:09,250 --> 00:14:11,518
were gonna be in
the pot with the blue tag
302
00:14:11,619 --> 00:14:15,189
and the asters are gonna be
in the pot with the yellow tag.
303
00:14:15,289 --> 00:14:17,524
[Jay] With the Olympics
less than a year away,
304
00:14:17,591 --> 00:14:20,194
800 people are needed
for the final push
305
00:14:20,294 --> 00:14:23,363
to finish the building's
crowning glory--
306
00:14:23,430 --> 00:14:25,432
the steeply sloping roof.
307
00:14:25,565 --> 00:14:28,202
At times it was tough
when we were working up here.
308
00:14:28,268 --> 00:14:30,671
The biggest challenge
creating this space
309
00:14:30,771 --> 00:14:33,407
was the safety element.
310
00:14:33,507 --> 00:14:36,943
It was very cumbersome
and, uh, uncomfortable
311
00:14:37,077 --> 00:14:39,412
to be attached to a lifeline.
312
00:14:40,681 --> 00:14:44,318
But it was absolutely necessary
to work along the perimeter,
313
00:14:44,418 --> 00:14:47,087
which is about 50 feet
from the leading edge.
314
00:14:48,088 --> 00:14:50,457
[Jay] It takes months
of backbreaking work
315
00:14:50,591 --> 00:14:52,259
to complete the job.
316
00:14:52,359 --> 00:14:55,296
[Hannah] You are continually
bending over to plant.
317
00:14:55,429 --> 00:14:57,297
You had to move
at a decent pace.
318
00:14:57,397 --> 00:14:58,965
It was tough, but it was fun.
319
00:15:00,834 --> 00:15:04,972
[music]
320
00:15:05,072 --> 00:15:06,273
[Jay] In 2010,
321
00:15:06,373 --> 00:15:08,375
Vancouver Conference Centre West
322
00:15:08,475 --> 00:15:11,345
is revealed to
the world's press.
323
00:15:11,445 --> 00:15:13,246
The opening day
of the 2010 Olympics
324
00:15:13,346 --> 00:15:16,349
was such an exciting day.
325
00:15:16,483 --> 00:15:19,686
We were lucky to welcome people
from all over the world.
326
00:15:21,455 --> 00:15:24,024
[Jay] The 1.2
million-square-foot center
327
00:15:24,158 --> 00:15:26,694
has the largest
ballroom in Canada,
328
00:15:26,794 --> 00:15:30,531
and the main hall
can hold 15,000 people.
329
00:15:30,664 --> 00:15:33,933
But it's not just human
visitors it appeals to.
330
00:15:34,034 --> 00:15:35,168
[Daniel] The habitat
structure has
331
00:15:35,302 --> 00:15:36,637
a lot of marine life
growing on it.
332
00:15:36,737 --> 00:15:38,839
And that marine life
actually grew much faster
333
00:15:38,939 --> 00:15:42,376
than anybody anticipated
within months of construction.
334
00:15:42,476 --> 00:15:45,145
And it's continued on
over the past 14 years.
335
00:15:46,981 --> 00:15:48,682
[Jay] The roof
has also flourished
336
00:15:48,816 --> 00:15:50,651
and is attracting pollinators.
337
00:15:50,784 --> 00:15:53,186
And, irrigated by
recycled wastewater,
338
00:15:53,320 --> 00:15:54,555
it's helped to make the center
339
00:15:54,655 --> 00:15:58,358
one of North America's
greenest buildings.
340
00:15:58,458 --> 00:15:59,493
[Craig] The building
is currently related as
341
00:15:59,627 --> 00:16:00,927
a EE Platinum.
342
00:16:00,994 --> 00:16:04,264
And that is the highest standard
of sustainability rating
343
00:16:04,364 --> 00:16:07,534
you can get as
a building like this.
344
00:16:07,634 --> 00:16:09,236
[Mark] It's an
emotional experience,
345
00:16:09,370 --> 00:16:12,840
to see a building
that is occupied by fish
346
00:16:12,906 --> 00:16:16,043
and by bees
and by birds and by plants
347
00:16:16,143 --> 00:16:18,545
and by humans.
348
00:16:18,679 --> 00:16:20,948
Working on the Vancouver
Convention Centre,
349
00:16:21,048 --> 00:16:26,220
it was a reminder of
how deeply interconnected
350
00:16:26,353 --> 00:16:28,521
everything in our world is.
351
00:16:32,025 --> 00:16:38,598
[music]
352
00:16:39,766 --> 00:16:41,602
When the beautiful
French city of Bordeaux
353
00:16:41,702 --> 00:16:44,071
needed a new bridge
across the river Garonne,
354
00:16:44,171 --> 00:16:46,406
they didn't want some
regular, boring bridge,
355
00:16:46,506 --> 00:16:47,741
something that
just carried vehicles
356
00:16:47,875 --> 00:16:50,243
from one side of
the river to the other.
357
00:16:50,377 --> 00:16:51,912
Where's the fun in that?
358
00:16:52,012 --> 00:16:54,515
No, they wanted
something different.
359
00:16:54,615 --> 00:16:55,883
So different, in fact,
360
00:16:56,016 --> 00:16:58,052
that when elevated to allow
tall ships to pass below,
361
00:16:58,185 --> 00:17:00,220
it doesn't look much
like a bridge at all.
362
00:17:00,354 --> 00:17:02,823
It looks more
like a work of art,
363
00:17:02,923 --> 00:17:06,159
which it most definitely is.
364
00:17:08,128 --> 00:17:09,663
[Jay] This is the magnificent
365
00:17:09,797 --> 00:17:12,132
Jacques Chaban Delmas Bridge.
366
00:17:12,232 --> 00:17:15,135
[music]
367
00:17:15,269 --> 00:17:16,770
[Dr. Mabry] Watching it open,
368
00:17:16,870 --> 00:17:19,440
you feel like you're in, like,
one of the Transformers movies.
369
00:17:19,540 --> 00:17:20,774
[Jay] A mechanical marvel
370
00:17:20,874 --> 00:17:22,977
that can lift
eight lanes of roadway
371
00:17:23,110 --> 00:17:25,579
160 feet.
372
00:17:25,679 --> 00:17:28,582
It's like it was alive, no?
This bridge.
373
00:17:30,284 --> 00:17:32,286
[Jay] Built over
one of southwest France's
374
00:17:32,386 --> 00:17:34,054
busiest rivers.
375
00:17:34,154 --> 00:17:37,157
It was totally crazy, no?
376
00:17:37,290 --> 00:17:40,627
[Jay] It required
gravity-defying engineering.
377
00:17:40,760 --> 00:17:43,898
The bridge lifting span
by itself
378
00:17:43,998 --> 00:17:46,433
weighs around 5 million pounds.
379
00:17:49,603 --> 00:17:53,607
[Jay] It now stands as Europe's
tallest vertical lift bridge.
380
00:17:57,411 --> 00:17:59,512
So, how did they build it?
381
00:18:06,287 --> 00:18:07,621
[Jay] It's 2008,
382
00:18:07,721 --> 00:18:10,056
and the beautiful,
historic city of Bordeaux
383
00:18:10,190 --> 00:18:12,359
in southwest France is changing.
384
00:18:14,528 --> 00:18:16,630
Historically,
development was concentrated
385
00:18:16,730 --> 00:18:20,200
on the left bank
of the river Garonne.
386
00:18:20,333 --> 00:18:24,704
But now, new neighborhoods are
springing up across the water.
387
00:18:24,805 --> 00:18:26,173
As Bordeaux grows,
388
00:18:26,273 --> 00:18:30,777
traffic is becoming
a bigger and bigger problem.
389
00:18:30,844 --> 00:18:34,548
The city is one of
the most congested in France,
390
00:18:34,648 --> 00:18:36,350
and its transport
infrastructure,
391
00:18:36,450 --> 00:18:37,951
especially its bridges,
392
00:18:38,051 --> 00:18:39,352
are at a breaking point.
393
00:18:40,521 --> 00:18:46,059
[speaking French]
394
00:18:47,695 --> 00:18:50,498
[Jay] The city
needs a new bridge.
395
00:18:50,598 --> 00:18:53,033
But the ideal spot to build one
396
00:18:53,133 --> 00:18:55,602
is over a part of
the river used by cruise ships
397
00:18:55,702 --> 00:18:58,872
to access
the city's historic port.
398
00:18:59,006 --> 00:19:00,507
The requirements
were to design a bridge
399
00:19:00,607 --> 00:19:02,475
that could allow
tall ships to pass
400
00:19:02,575 --> 00:19:06,680
and carry pedestrians and cars
and a tram in the future.
401
00:19:07,781 --> 00:19:09,449
[Jay] They can't
just build a high bridge
402
00:19:09,549 --> 00:19:12,319
because it needs to connect
to the existing roads
403
00:19:12,420 --> 00:19:13,954
on the riverbank.
404
00:19:14,054 --> 00:19:16,623
So, they settle on
what's known as
405
00:19:16,723 --> 00:19:19,026
a vertical lifting bridge.
406
00:19:19,092 --> 00:19:20,961
A vertical
lifting bridge is when
407
00:19:21,061 --> 00:19:25,065
the whole central span
lifts straight up into the air.
408
00:19:25,165 --> 00:19:27,401
The problem is
that it usually takes
409
00:19:27,501 --> 00:19:29,703
a whole lot of clunky
mechanical gear
410
00:19:29,803 --> 00:19:31,238
in order to make it possible.
411
00:19:31,338 --> 00:19:33,106
So they're like
the ugly ducklings
412
00:19:33,207 --> 00:19:35,209
of the bridge world.
413
00:19:35,309 --> 00:19:37,110
[Jay] While a vertical
lifting bridge
414
00:19:37,244 --> 00:19:38,979
might be what the city needs,
415
00:19:39,079 --> 00:19:44,051
an ugly duckling is
the last thing it wants.
416
00:19:44,117 --> 00:19:45,485
[Cecilia]
The town of Bordeaux,
417
00:19:45,585 --> 00:19:48,955
it is a 18th century
historical town
418
00:19:49,055 --> 00:19:52,259
with a harmony and a skyline.
419
00:19:52,393 --> 00:19:54,561
Super beautiful.
420
00:19:54,662 --> 00:19:58,499
And the bridge
will be the middle,
421
00:19:58,599 --> 00:20:01,768
so the project
must be in harmony.
422
00:20:02,769 --> 00:20:04,104
[Jay] The specialist
bridge architects
423
00:20:04,204 --> 00:20:06,540
take inspiration
from the steeples
424
00:20:06,640 --> 00:20:09,242
of Bordeaux's
many ancient churches.
425
00:20:10,745 --> 00:20:12,746
[Cecilia]
It was the adrenaline moment
426
00:20:12,846 --> 00:20:15,115
to find
the design of the pylons.
427
00:20:15,249 --> 00:20:18,585
It was so...exciting.
[laughs]
428
00:20:22,255 --> 00:20:24,692
[music]
429
00:20:24,792 --> 00:20:27,794
[Jay] The design combines
beauty and practicality.
430
00:20:27,928 --> 00:20:31,665
But building it won't be easy.
431
00:20:31,765 --> 00:20:33,300
Working on the busy river,
432
00:20:33,433 --> 00:20:36,303
they'll need to create
foundations in the water
433
00:20:36,403 --> 00:20:39,073
and find a way
to protect it from being hit
434
00:20:39,173 --> 00:20:41,675
by passing ships
435
00:20:41,776 --> 00:20:44,544
before constructing
four elegant,
436
00:20:44,644 --> 00:20:47,681
250-foot-tall pylons.
437
00:20:47,748 --> 00:20:50,818
The massive road deck will have
to be brought in in sections
438
00:20:50,918 --> 00:20:52,519
and carefully positioned.
439
00:20:53,920 --> 00:20:55,823
Then, they'll need
a lifting system
440
00:20:55,923 --> 00:20:59,693
that's small enough to be
hidden inside the towers,
441
00:20:59,793 --> 00:21:01,595
but powerful enough to lift
442
00:21:01,695 --> 00:21:05,466
the huge
2750-ton central section,
443
00:21:05,566 --> 00:21:08,268
which will carry
eight lanes of traffic,
444
00:21:08,368 --> 00:21:11,605
as well as pedestrians
and cyclists.
445
00:21:11,705 --> 00:21:14,941
It will be a mammoth test
for the whole team.
446
00:21:15,776 --> 00:21:21,181
[speaking French]
447
00:21:28,489 --> 00:21:32,125
I was a little bit,
uh, afraid, too.
448
00:21:32,225 --> 00:21:33,893
Uh...[laughs]
449
00:21:34,027 --> 00:21:35,695
It was stretch for me.
450
00:21:38,398 --> 00:21:40,734
[Jay] It's October 2009.
451
00:21:40,868 --> 00:21:42,002
Construction begins,
452
00:21:42,102 --> 00:21:43,637
and immediately
the team is faced with
453
00:21:43,737 --> 00:21:46,073
its first challenge--
454
00:21:46,173 --> 00:21:48,375
creating underwater
concrete foundations
455
00:21:48,509 --> 00:21:50,043
that will be
strong enough to hold up
456
00:21:50,143 --> 00:21:53,914
four 250-foot-tall
concrete pylons.
457
00:21:55,916 --> 00:21:58,051
Building the foundations
of a bridge over deep water
458
00:21:58,185 --> 00:21:59,953
is always challenging.
459
00:22:01,955 --> 00:22:03,457
[Jay] Because
the river's busy here,
460
00:22:03,557 --> 00:22:05,292
it's even more complicated.
461
00:22:05,392 --> 00:22:07,360
Rather than create
the foundations on site,
462
00:22:07,461 --> 00:22:11,331
they plan to prefabricate
six concrete foundation boxes
463
00:22:11,431 --> 00:22:13,734
in a dry dock up the river.
464
00:22:13,834 --> 00:22:16,336
Then they'll float
them into position
465
00:22:16,436 --> 00:22:19,906
and secure them to piles
sunk into the riverbed.
466
00:22:20,040 --> 00:22:23,743
The two largest boxes will
become the bridge foundations.
467
00:22:23,844 --> 00:22:26,113
The four smaller ones are
there to protect the structure
468
00:22:26,246 --> 00:22:27,948
from potential ship impacts.
469
00:22:33,220 --> 00:22:36,023
In 2010, 3 miles
from the bridge site,
470
00:22:36,123 --> 00:22:38,625
the team starts to
work on the boxes.
471
00:22:40,393 --> 00:22:44,898
Each will be made using between
3000 to 6000 tons of concrete
472
00:22:44,998 --> 00:22:47,267
reinforced with steel.
473
00:22:47,400 --> 00:22:49,936
And they're working
against the clock.
474
00:22:51,772 --> 00:22:56,176
[speaking French]
475
00:23:11,591 --> 00:23:12,759
[Jay] After five months,
476
00:23:12,860 --> 00:23:15,429
the first foundation
boxes are ready.
477
00:23:15,529 --> 00:23:17,665
The dry dock is flooded,
478
00:23:17,765 --> 00:23:21,601
and then they set out
along the Garonne.
479
00:23:21,702 --> 00:23:23,570
It's a tense moment
for the team.
480
00:23:26,440 --> 00:23:30,944
[speaking French]
481
00:23:38,619 --> 00:23:39,920
[Jay] To keep the boxes steady,
482
00:23:40,020 --> 00:23:43,023
each needs
two tugs pulling it.
483
00:23:43,123 --> 00:23:45,025
Navigating
the carefully planned route,
484
00:23:45,158 --> 00:23:48,895
avoiding sandbanks
and the most dangerous currents,
485
00:23:48,995 --> 00:23:50,631
takes four days and nights,
486
00:23:50,731 --> 00:23:52,866
with the team working in shifts.
487
00:23:52,999 --> 00:23:59,339
[music]
488
00:23:59,472 --> 00:24:02,943
[Jay] Now the box can be
carefully slotted into place
489
00:24:03,043 --> 00:24:07,247
and flooded with water
to sink it to the waterbed.
490
00:24:07,381 --> 00:24:09,883
Then, the water
is replaced with concrete
491
00:24:09,983 --> 00:24:11,451
to make it permanent.
492
00:24:13,253 --> 00:24:18,458
[speaking French]
493
00:24:28,068 --> 00:24:29,269
[Jay] Over the next few weeks,
494
00:24:29,403 --> 00:24:31,972
the rest of the boxes follow,
495
00:24:32,072 --> 00:24:36,010
and the team begins work on the
four reinforced concrete pylons.
496
00:24:36,076 --> 00:24:41,115
[music]
497
00:24:41,215 --> 00:24:44,952
[Jay] Next, though, is possibly
the team's greatest challenge--
498
00:24:45,085 --> 00:24:47,487
creating the road that
will run between them.
499
00:24:49,390 --> 00:24:51,658
The crossing will be made
of smaller fixed sections
500
00:24:51,758 --> 00:24:54,128
on each side acting as ramps
501
00:24:54,261 --> 00:24:58,132
and a massive middle
section 380 feet long
502
00:24:58,232 --> 00:25:00,634
that will rise and lower.
503
00:25:00,734 --> 00:25:04,071
So 120 meters long,
30 meters wide,
504
00:25:04,171 --> 00:25:08,341
uh, 2500 tons of steel,
505
00:25:08,475 --> 00:25:11,845
and, uh, and in one piece,
so it was crazy.
506
00:25:13,481 --> 00:25:15,649
[Jay] What makes
things even trickier
507
00:25:15,749 --> 00:25:19,520
is that the only company that
can make these massive slabs
508
00:25:19,620 --> 00:25:22,656
is based in Venice, Italy.
509
00:25:22,756 --> 00:25:24,324
These sections are so big
510
00:25:24,424 --> 00:25:26,359
that they can't be
brought by road.
511
00:25:26,459 --> 00:25:28,194
They have to be floated to site.
512
00:25:30,797 --> 00:25:34,034
[Jay] Only, this journey
is a 3000-mile trip
513
00:25:34,167 --> 00:25:35,869
across the Mediterranean Sea
514
00:25:35,969 --> 00:25:38,472
and into the Atlantic Ocean,
515
00:25:38,572 --> 00:25:41,408
and it's not easy sailing.
516
00:25:41,475 --> 00:25:45,612
[speaking French]
517
00:25:58,125 --> 00:26:00,928
[Jay] But, after
three tense weeks at sea,
518
00:26:01,028 --> 00:26:03,364
the decks finally
arrive on site,
519
00:26:03,464 --> 00:26:05,399
ready to be fitted.
520
00:26:05,532 --> 00:26:07,734
That's if the team
can find an opening
521
00:26:07,868 --> 00:26:09,936
in the river's hectic schedule.
522
00:26:11,572 --> 00:26:13,540
The Garonne is a
very busy river.
523
00:26:13,640 --> 00:26:16,009
It was not permissible
to block the channel
524
00:26:16,109 --> 00:26:17,711
for long periods of time.
525
00:26:17,844 --> 00:26:21,215
[music]
526
00:26:21,315 --> 00:26:25,886
[Jay] The team needs to lift
this 2500-ton slab into position
527
00:26:25,986 --> 00:26:28,121
as quickly as possible.
528
00:26:28,221 --> 00:26:29,723
It's too heavy for a crane,
529
00:26:29,823 --> 00:26:32,926
so, once again, they turn
to the river for help.
530
00:26:35,395 --> 00:26:37,898
On a high tide,
the barge will float the spans
531
00:26:37,998 --> 00:26:40,234
above their final position.
532
00:26:40,334 --> 00:26:42,603
Winches will take them
through 90 degrees
533
00:26:42,703 --> 00:26:44,504
to line up with
the fixing points.
534
00:26:44,605 --> 00:26:49,076
Then, wait for the tide to fall
and lock them back in place.
535
00:26:49,176 --> 00:26:51,912
But the tides
have to be just right.
536
00:26:55,715 --> 00:27:02,289
[music]
537
00:27:07,928 --> 00:27:09,496
[Jay] In Bordeaux,
538
00:27:09,629 --> 00:27:11,732
the team building
a vertical lifting bridge
539
00:27:11,832 --> 00:27:13,066
over the river Garonne
540
00:27:13,166 --> 00:27:15,636
is relying on the tides
to help them position
541
00:27:15,736 --> 00:27:17,571
the enormous central span.
542
00:27:21,074 --> 00:27:23,911
It's a clear morning
in the summer of 2012.
543
00:27:24,011 --> 00:27:26,280
The tides are set to be perfect.
544
00:27:26,413 --> 00:27:28,815
And the city is watching.
545
00:27:28,949 --> 00:27:32,285
A lot of people in Bordeaux
was here to see this moment.
546
00:27:34,454 --> 00:27:35,789
[Jay]
The high tide helps to float
547
00:27:35,889 --> 00:27:40,627
the 380-foot-long
central span into position.
548
00:27:40,727 --> 00:27:45,432
It must be inched into place
with pinpoint accuracy.
549
00:27:45,532 --> 00:27:46,967
As the tide falls again,
550
00:27:47,067 --> 00:27:52,239
the central piece locks
onto the pylons perfectly.
551
00:27:52,306 --> 00:27:55,642
It was a fantastic moment.
552
00:27:56,443 --> 00:27:58,779
[music]
553
00:27:58,879 --> 00:28:02,583
[Jay] Now the team
faces its final challenge--
554
00:28:02,683 --> 00:28:04,618
making sure this
huge central span
555
00:28:04,685 --> 00:28:08,054
can be lifted
effortlessly into the air.
556
00:28:08,188 --> 00:28:13,160
The lifting span by itself
weighs about 5 million pounds.
557
00:28:13,260 --> 00:28:14,695
In order to raise that,
558
00:28:14,795 --> 00:28:17,898
that's an incredible
amount of energy.
559
00:28:18,032 --> 00:28:19,967
[Jay] As if that
wasn't tough enough,
560
00:28:20,067 --> 00:28:21,835
the lifting system
needs to fit into
561
00:28:21,969 --> 00:28:26,106
the bridge's elegant,
narrow pylons.
562
00:28:26,206 --> 00:28:28,708
The secret to
this phenomenal deadlift
563
00:28:28,809 --> 00:28:31,211
is counterweights.
564
00:28:31,344 --> 00:28:34,047
[Dr. Mabry] Counterweights
are an engineer's ace card.
565
00:28:34,147 --> 00:28:36,316
By balancing the weight
of what you're lifting
566
00:28:36,416 --> 00:28:39,720
with something almost as heavy
moving in opposition to it,
567
00:28:39,854 --> 00:28:42,088
you can minimize
the lifting force needed.
568
00:28:43,857 --> 00:28:46,059
[Jay] The team calculates
that in each tower,
569
00:28:46,159 --> 00:28:50,531
they need
a 660-ton counterweight,
570
00:28:50,664 --> 00:28:54,001
supported by
four massive pulley wheels
571
00:28:54,101 --> 00:28:56,436
with super-reinforced cables.
572
00:28:56,537 --> 00:28:59,473
We were able to create a very,
very long, thin counterweight,
573
00:28:59,573 --> 00:29:03,310
which is, uh, not typical
in a vertical lift bridge.
574
00:29:03,410 --> 00:29:06,013
[Jay] If they've
got the balancing act right,
575
00:29:06,079 --> 00:29:08,648
they'll only need
four modest engines
576
00:29:08,748 --> 00:29:11,285
to lift the enormous bridge.
577
00:29:11,385 --> 00:29:14,621
Those motors are actually
only 150 horsepower
578
00:29:14,754 --> 00:29:16,424
due to the balance
that we were able to achieve,
579
00:29:16,524 --> 00:29:19,259
which greatly reduces
the power consumption.
580
00:29:19,359 --> 00:29:20,894
[Jay] Good for the
city's energy bill
581
00:29:20,994 --> 00:29:22,596
and good for the planet.
582
00:29:22,730 --> 00:29:24,532
You can move the bridge
with one hand, huh.
583
00:29:24,632 --> 00:29:26,867
You know, it's, uh, it's crazy.
584
00:29:30,003 --> 00:29:32,339
[Jay] March 17, 2013,
585
00:29:32,440 --> 00:29:36,076
and the bridge
is finally finished.
586
00:29:36,176 --> 00:29:39,513
After 10 years of planning,
design, and construction,
587
00:29:39,613 --> 00:29:41,014
it's time for
the people of Bordeaux
588
00:29:41,081 --> 00:29:42,983
to test their new bridge.
589
00:29:44,385 --> 00:29:49,422
[speaking French]
590
00:29:52,025 --> 00:29:54,628
[music]
591
00:29:54,728 --> 00:29:56,630
The bridge opened flawlessly.
592
00:29:56,730 --> 00:30:00,100
The French military sailboat
came through the bridge,
593
00:30:00,233 --> 00:30:03,503
a beautiful image.
594
00:30:03,604 --> 00:30:05,505
[Thomas]
The first time I see it go up,
595
00:30:05,605 --> 00:30:10,411
I remember that, uh,
there was no noise, nothing.
596
00:30:10,544 --> 00:30:12,379
It's beautiful, yeah.
597
00:30:12,479 --> 00:30:15,182
[Jay] The bridge,
combined with a new tram system,
598
00:30:15,282 --> 00:30:16,950
has helped ease traffic
599
00:30:17,050 --> 00:30:20,353
in what was one of France's
most congested cities.
600
00:30:20,454 --> 00:30:24,191
And it continues to perform
staggering feats of strength
601
00:30:24,291 --> 00:30:26,860
with faultless elegance.
602
00:30:26,927 --> 00:30:30,597
We cannot build
anything better than this...
603
00:30:30,697 --> 00:30:32,999
than this...than
this bridge here.
604
00:30:35,602 --> 00:30:38,038
[Paul] We did something
great together.
605
00:30:38,105 --> 00:30:39,906
Wow, we did it.
606
00:30:40,006 --> 00:30:45,011
[music]
607
00:30:45,879 --> 00:30:51,484
[music]
608
00:30:53,087 --> 00:30:54,588
Think you know
what a school looks like?
609
00:30:54,688 --> 00:30:56,790
Well, visit Tokyo
and think again
610
00:30:56,890 --> 00:30:58,425
because this
stunning tower houses
611
00:30:58,525 --> 00:31:00,961
not one,
but three separate schools
612
00:31:01,094 --> 00:31:05,332
and 10,000 students within
its super-strong cocoon design,
613
00:31:05,465 --> 00:31:08,134
as well as
a retractable helipad.
614
00:31:08,234 --> 00:31:09,769
Helicopters on
the run to school?
615
00:31:09,870 --> 00:31:10,971
Wow.
616
00:31:11,104 --> 00:31:12,105
Oh, and if you're wondering
617
00:31:12,205 --> 00:31:14,074
just how strong
super strong is,
618
00:31:14,175 --> 00:31:19,146
in 2011, the tower was caught
in a magnitude 9.1 earthquake.
619
00:31:19,246 --> 00:31:20,647
Structural damage?
620
00:31:20,781 --> 00:31:21,848
Zero.
621
00:31:21,948 --> 00:31:24,818
[music]
622
00:31:24,918 --> 00:31:27,287
[Jay] Introducing Mode Gakuyen,
623
00:31:27,387 --> 00:31:30,657
or the Cocoon,
as it's affectionately known.
624
00:31:30,757 --> 00:31:33,593
This building really
just looks beautiful.
625
00:31:33,693 --> 00:31:35,896
[Jay] One of the tallest
colleges in the world,
626
00:31:35,996 --> 00:31:38,432
it's as clever
as it is stunning.
627
00:31:38,499 --> 00:31:42,002
This building has
a retractable roof
628
00:31:42,135 --> 00:31:45,806
that helicopters
can also land on.
629
00:31:45,939 --> 00:31:47,574
Did you have that
at your university?
630
00:31:47,674 --> 00:31:49,009
'Cause I didn't.
631
00:31:50,611 --> 00:31:54,047
[Jay] With a design that
was breathtakingly ambitious...
632
00:31:55,950 --> 00:31:59,753
[speaking Japanese]
633
00:32:03,023 --> 00:32:04,491
[Masato]
When I first saw the design,
634
00:32:04,591 --> 00:32:06,793
I thought it was
a good challenge.
635
00:32:08,495 --> 00:32:12,066
[Jay] ...it would take every
ounce of ingenuity and effort
636
00:32:12,166 --> 00:32:13,634
to finish it.
637
00:32:13,734 --> 00:32:16,970
Making a structure
as complex as this
638
00:32:17,070 --> 00:32:18,171
is exhausting.
639
00:32:20,340 --> 00:32:21,742
[Jay] Yet the final result
640
00:32:21,842 --> 00:32:23,811
would transform
the Tokyo skyline
641
00:32:23,911 --> 00:32:27,214
with a skyscraper
unlike any other,
642
00:32:27,347 --> 00:32:30,618
loved by those who use it.
643
00:32:30,718 --> 00:32:33,420
This building is
a very iconic place
644
00:32:33,520 --> 00:32:37,024
and I really love to study here.
645
00:32:37,124 --> 00:32:39,693
[Jay] So, how did they build it?
646
00:32:43,730 --> 00:32:46,934
[music]
647
00:32:47,068 --> 00:32:48,669
[Jay] At the end
of the 20th century,
648
00:32:48,769 --> 00:32:51,071
Japan was languishing
in a recession.
649
00:32:52,105 --> 00:32:53,941
But by the mid 2000s,
650
00:32:54,041 --> 00:32:57,077
there are signs of
a burgeoning recovery.
651
00:32:57,178 --> 00:32:58,712
Investment is up,
652
00:32:58,812 --> 00:33:02,082
and people are beginning to
feel positive about the future.
653
00:33:02,182 --> 00:33:04,818
So, the Japan
Educational Foundation
654
00:33:04,918 --> 00:33:09,156
decides now is
the perfect time to expand.
655
00:33:09,290 --> 00:33:12,325
[speaking Japanese]
656
00:33:22,236 --> 00:33:24,971
[Jay] In one of the world's most
densely populated countries,
657
00:33:25,105 --> 00:33:28,308
finding space to build is tough.
658
00:33:28,408 --> 00:33:30,811
The plot they found
is less than an acre,
659
00:33:30,944 --> 00:33:35,315
and on it, they've gotta
fit three new colleges.
660
00:33:35,448 --> 00:33:39,319
The lands were not as big
as we would like to be.
661
00:33:40,320 --> 00:33:42,222
[Dr. Agbedor]
Space for development in Japan
662
00:33:42,322 --> 00:33:43,456
is premium.
663
00:33:43,556 --> 00:33:45,459
If you wanna build
anything here,
664
00:33:45,593 --> 00:33:49,396
you have to be
an incredible problem solver.
665
00:33:49,496 --> 00:33:51,898
[Jay] The man tasked with
finding the solution
666
00:33:51,998 --> 00:33:54,134
is architect Paul Tange.
667
00:33:54,234 --> 00:33:58,805
Of course there is
a functional requirement.
668
00:33:58,939 --> 00:34:00,641
But they wanted to see something
669
00:34:00,741 --> 00:34:02,643
that they have
never seen before.
670
00:34:03,511 --> 00:34:07,481
We finally came up with
the idea of cocoon.
671
00:34:07,581 --> 00:34:09,616
[Jay] The inspiration
for the cocoon design
672
00:34:09,716 --> 00:34:12,552
comes from the students
that will study here.
673
00:34:12,652 --> 00:34:15,789
We nourish them, cherish them,
674
00:34:15,889 --> 00:34:18,358
give them everything
we have, knowledge,
675
00:34:18,491 --> 00:34:23,563
and eventually they will
come to beautiful butterfly
676
00:34:23,697 --> 00:34:25,765
and then fly off to the world.
677
00:34:28,168 --> 00:34:30,437
[Jay] Constructing a building
that looks like a cocoon
678
00:34:30,537 --> 00:34:34,608
will demand ingenious design
and creative engineering.
679
00:34:34,675 --> 00:34:37,010
First, it's gonna be
a very big building
680
00:34:37,110 --> 00:34:38,379
in a earthquake zone,
681
00:34:38,479 --> 00:34:42,582
so its foundations
need to be super strong.
682
00:34:42,682 --> 00:34:47,053
Then, they will have to work out
how to squeeze 10,000 students
683
00:34:47,153 --> 00:34:51,258
into one building on
a site that isn't big enough.
684
00:34:51,391 --> 00:34:53,994
Next, they'll wanna
construct a curtain wall
685
00:34:54,094 --> 00:34:56,063
from huge glass panels,
686
00:34:56,163 --> 00:35:00,167
somehow using them to create
the natural look of a cocoon.
687
00:35:00,267 --> 00:35:02,402
Finally, they'll have
to work out how to land
688
00:35:02,503 --> 00:35:06,607
an emergency helicopter on
a building with a curved top.
689
00:35:06,707 --> 00:35:09,643
The design Tange and the team
come up with is incredible,
690
00:35:09,743 --> 00:35:11,978
but there's a huge problem.
691
00:35:13,146 --> 00:35:15,348
[Dr. Agbedor] They've got
a beautiful design,
692
00:35:15,448 --> 00:35:17,651
something that
makes a skyscraper
693
00:35:17,785 --> 00:35:20,254
look like a work of art.
694
00:35:20,354 --> 00:35:21,989
But they can't build it.
695
00:35:22,122 --> 00:35:23,790
Japanese building regulations
696
00:35:23,890 --> 00:35:25,158
won't allow them
to build something
697
00:35:25,292 --> 00:35:27,828
the size that they need.
698
00:35:27,961 --> 00:35:29,630
[Jay] In Japan,
there are tight restrictions
699
00:35:29,763 --> 00:35:31,966
on how large
you can build skyscrapers
700
00:35:32,099 --> 00:35:35,969
to stop them from
blocking sunlight and air flow.
701
00:35:36,103 --> 00:35:37,938
But fitting in 10,000 students
702
00:35:38,072 --> 00:35:40,274
means they need to
exceed the restrictions
703
00:35:40,374 --> 00:35:42,276
in a big way.
704
00:35:42,376 --> 00:35:44,144
It's almost more than 30%,
705
00:35:44,277 --> 00:35:46,813
which is quite a lot to achieve.
706
00:35:46,947 --> 00:35:48,616
[Jay] After lengthy discussions,
707
00:35:48,749 --> 00:35:51,117
the architects manage
to persuade the government
708
00:35:51,251 --> 00:35:54,789
that this area of Tokyo needs
more young, talented people,
709
00:35:54,922 --> 00:35:56,856
and they get the go-ahead.
710
00:35:59,593 --> 00:36:02,729
In May 2006,
construction begins,
711
00:36:02,862 --> 00:36:05,565
and with it comes
the first major challenge.
712
00:36:07,234 --> 00:36:10,504
Much of Tokyo is built
on clay, silt, and sand,
713
00:36:10,604 --> 00:36:13,507
which is too soft
to support an enormous building
714
00:36:13,607 --> 00:36:15,342
like the cocoon.
715
00:36:15,442 --> 00:36:19,280
We knew that the soil
under the foundation
716
00:36:19,380 --> 00:36:22,115
was not strong enough
717
00:36:22,215 --> 00:36:25,819
to support the weight
of the tall building.
718
00:36:27,120 --> 00:36:28,255
[Jay] The first
thing they have to do
719
00:36:28,355 --> 00:36:30,657
is dig down to
find solid ground.
720
00:36:32,126 --> 00:36:33,627
We used piling,
721
00:36:33,728 --> 00:36:36,896
so that piles
were reached deeper soil,
722
00:36:36,997 --> 00:36:38,265
which is stronger.
723
00:36:38,365 --> 00:36:40,801
Then the stronger
soil can support
724
00:36:40,868 --> 00:36:42,502
the weight of the building
725
00:36:42,636 --> 00:36:44,704
so that the building
doesn't sink.
726
00:36:46,173 --> 00:36:48,542
[Jay] Once they have
created the 36 piles,
727
00:36:48,642 --> 00:36:51,178
they lay
a huge slab across the top
728
00:36:51,278 --> 00:36:54,114
to bond them all together.
729
00:36:54,214 --> 00:36:56,851
The concrete slab,
it transfers
730
00:36:56,951 --> 00:36:59,052
the weight of the building
731
00:36:59,186 --> 00:37:01,121
to the soil directly.
732
00:37:02,089 --> 00:37:03,524
[Jay] In July 2006,
733
00:37:03,624 --> 00:37:05,626
they finally have
a solid foundation
734
00:37:05,760 --> 00:37:08,495
to build
the 668-foot-tall building.
735
00:37:10,764 --> 00:37:13,267
Now they can start on the tower.
736
00:37:13,367 --> 00:37:16,103
With the small plot size,
it will start narrow,
737
00:37:16,203 --> 00:37:18,205
allowing
light down to the street,
738
00:37:18,272 --> 00:37:22,276
and then bulge in the middle
to allow for more floor space.
739
00:37:22,376 --> 00:37:25,412
But the curving shape
makes it complicated to build,
740
00:37:25,512 --> 00:37:29,383
especially in a country that's
known for huge earthquakes.
741
00:37:29,449 --> 00:37:31,251
Curved structures
are at great risk
742
00:37:31,351 --> 00:37:33,286
of twisting during
an earthquake.
743
00:37:33,420 --> 00:37:35,188
That's called torsional forces.
744
00:37:35,288 --> 00:37:36,289
So you've gotta make sure
745
00:37:36,390 --> 00:37:38,158
that your
beautifully designed building
746
00:37:38,258 --> 00:37:40,094
doesn't essentially
rip itself apart.
747
00:37:40,227 --> 00:37:46,466
[music]
748
00:37:51,672 --> 00:37:53,107
[Jay] In Tokyo,
the team building
749
00:37:53,240 --> 00:37:55,742
a curving,
cocoon-shaped skyscraper
750
00:37:55,843 --> 00:37:58,712
needs to make it strong enough
to withstand earthquakes.
751
00:38:00,547 --> 00:38:04,351
They decide to wrap the tower
in a strong steel exoskeleton
752
00:38:04,485 --> 00:38:06,052
made from triangles.
753
00:38:06,152 --> 00:38:09,890
Known as a diagrid,
this will resist any tremors.
754
00:38:09,990 --> 00:38:13,327
Triangular frame
is much stronger than
755
00:38:13,427 --> 00:38:14,828
rectangular frame,
756
00:38:14,962 --> 00:38:18,833
because triangle is
very difficult to deflect
757
00:38:18,933 --> 00:38:22,135
compared to the rectangle.
758
00:38:22,236 --> 00:38:26,907
Covering the building with
triangular, or diagrid, frame
759
00:38:27,007 --> 00:38:31,745
was advantageous
against the lateral force.
760
00:38:31,846 --> 00:38:34,581
[Corina] It's like a web of
triangles all joined together.
761
00:38:34,681 --> 00:38:36,249
And as they push up
against each other,
762
00:38:36,349 --> 00:38:37,884
they support one another.
763
00:38:39,053 --> 00:38:40,554
[Jay] The steel diagrid frame
764
00:38:40,654 --> 00:38:44,191
is then tied into a
central concrete and steel core
765
00:38:44,325 --> 00:38:46,359
to make the building
even stronger.
766
00:38:47,961 --> 00:38:52,099
The inner frame is mainly
against the gravity laws
767
00:38:52,199 --> 00:38:53,700
and the external frame
768
00:38:53,800 --> 00:38:57,070
is mainly against
the lateral forces.
769
00:38:58,239 --> 00:39:00,007
[Jay] In February 2008,
770
00:39:00,140 --> 00:39:03,310
they now have a building
that is strong enough.
771
00:39:03,410 --> 00:39:05,512
The next challenge
is creating the curtain wall
772
00:39:05,612 --> 00:39:10,383
from approximately
3600 glass panels.
773
00:39:10,483 --> 00:39:14,254
Because the panels are big,
an entire story high,
774
00:39:14,388 --> 00:39:17,524
it will be difficult to
transport the complete panels
775
00:39:17,624 --> 00:39:21,195
through the congested,
narrow streets of Tokyo.
776
00:39:21,295 --> 00:39:24,698
It was decided to
assemble on site
777
00:39:24,764 --> 00:39:28,034
rather than transporting
the completed panel
778
00:39:28,168 --> 00:39:30,404
from the factory.
779
00:39:30,537 --> 00:39:31,972
[Jay] With such a small plot
780
00:39:32,072 --> 00:39:34,642
already jam packed
with construction activity,
781
00:39:34,742 --> 00:39:37,677
the problem now is
where to put them together.
782
00:39:37,778 --> 00:39:41,414
Ingeniously, they turn to
the empty elevator shaft area.
783
00:39:42,282 --> 00:39:44,084
The next challenge
is working out
784
00:39:44,184 --> 00:39:46,953
how to make the manmade
glass exterior of the building
785
00:39:47,053 --> 00:39:50,057
look like a natural cocoon.
786
00:39:50,157 --> 00:39:54,595
Nature does complex things
seemingly easily.
787
00:39:54,728 --> 00:39:57,231
And when humans
try to replicate it,
788
00:39:57,331 --> 00:39:59,399
then they realize
just how difficult
789
00:39:59,533 --> 00:40:01,001
it actually is.
790
00:40:02,636 --> 00:40:04,805
[Jay] Their clever solution
is to decorate the curtain wall
791
00:40:04,905 --> 00:40:07,908
with an organic pattern.
792
00:40:08,008 --> 00:40:10,911
The irregular patterns
within each curtain wall
793
00:40:11,011 --> 00:40:13,647
creates this amazing
optical illusion
794
00:40:13,748 --> 00:40:16,516
that you're looking
at a woven cocoon.
795
00:40:18,686 --> 00:40:20,721
[Jay] First,
they add strips of aluminum
796
00:40:20,821 --> 00:40:24,424
mirroring the diagrid
steels behind.
797
00:40:24,524 --> 00:40:26,626
From outside,
it looks like the same
798
00:40:26,726 --> 00:40:30,364
as the cross-bracing pattern.
799
00:40:30,464 --> 00:40:32,733
[Jay] Then, they add
dotted lines to the glass,
800
00:40:32,866 --> 00:40:36,036
which will come together
to form a randomized pattern
801
00:40:36,136 --> 00:40:39,773
resembling woven threads
crisscrossing the building.
802
00:40:39,873 --> 00:40:43,243
[Paul] We have to do it
with a computer to make sure
803
00:40:43,377 --> 00:40:45,979
as much as repetitive patterns,
804
00:40:46,079 --> 00:40:51,218
but create the better,
uh, irregular looks to it.
805
00:40:51,352 --> 00:40:54,087
So that was a,
a challenging part.
806
00:40:54,187 --> 00:40:56,389
[music]
807
00:40:56,523 --> 00:41:01,262
[Jay] It's also challenging
getting them up the building.
808
00:41:01,362 --> 00:41:02,929
[Paul] If there's a windy day,
809
00:41:03,030 --> 00:41:05,299
it's difficult
to bring up the pieces.
810
00:41:05,399 --> 00:41:08,035
It's very dangerous,
for that matter.
811
00:41:08,135 --> 00:41:09,803
[Jay] The panels might shatter,
812
00:41:09,937 --> 00:41:12,606
raining glass on people below.
813
00:41:12,706 --> 00:41:16,376
Again, the elevator shaft
comes to the rescue.
814
00:41:16,443 --> 00:41:20,213
They realize they can use it
to crane the panels to the top,
815
00:41:20,313 --> 00:41:22,082
protected from the wind.
816
00:41:22,182 --> 00:41:27,321
Each shaft is wind free,
which is quite safer place.
817
00:41:27,454 --> 00:41:29,156
[Jay] Now they can
just lower them
818
00:41:29,256 --> 00:41:30,991
a short distance into place.
819
00:41:31,091 --> 00:41:35,963
[music]
820
00:41:36,063 --> 00:41:37,431
[Jay]
Creating the curtain wall
821
00:41:37,531 --> 00:41:39,833
with its cocoon pattern.
822
00:41:39,933 --> 00:41:43,704
[music]
823
00:41:43,804 --> 00:41:45,573
[Jay] In March 2008,
824
00:41:45,639 --> 00:41:49,309
there is one final
hurdle to overcome.
825
00:41:49,409 --> 00:41:50,878
Every tall building in Japan
826
00:41:50,978 --> 00:41:52,812
has to have a platform
for helicopters
827
00:41:52,913 --> 00:41:55,315
in case of a fire.
828
00:41:55,415 --> 00:41:58,853
The architect
wanted a cocoon shape.
829
00:41:58,953 --> 00:42:04,025
They didn't like
to have a flat surface on top.
830
00:42:04,158 --> 00:42:07,561
So, it is a new challenge.
831
00:42:07,661 --> 00:42:10,230
[Jay] One for which
the team has a great solution.
832
00:42:10,330 --> 00:42:13,033
If they can't build it
on the roof of the building,
833
00:42:13,133 --> 00:42:15,970
then they will build
it inside the top.
834
00:42:16,070 --> 00:42:18,905
We designed a retractable roof.
835
00:42:21,875 --> 00:42:23,444
Back of the exoskeleton,
836
00:42:23,510 --> 00:42:26,880
there is a platform
already installed.
837
00:42:27,013 --> 00:42:30,517
Hovering space is supported by
838
00:42:30,617 --> 00:42:34,354
three pairs of cross-braces.
839
00:42:34,454 --> 00:42:37,057
The roof is opened
and closed manually
840
00:42:37,157 --> 00:42:40,026
by hand control in emergency.
841
00:42:42,629 --> 00:42:44,398
[Jay] Creating
a retracting platform
842
00:42:44,531 --> 00:42:48,668
that feels more
James Bond than Tokyo college.
843
00:42:54,208 --> 00:42:56,877
After two years
of creative construction
844
00:42:56,977 --> 00:42:59,013
and problem-solving engineering,
845
00:42:59,113 --> 00:43:00,847
in October 2008,
846
00:43:00,947 --> 00:43:04,250
the spectacular Cocoon Tower
throws open its doors
847
00:43:04,351 --> 00:43:08,789
to students attending Japan's
first vertical university.
848
00:43:08,889 --> 00:43:12,860
[music]
849
00:43:12,960 --> 00:43:17,464
The design of the cocoon
is very beautiful.
850
00:43:17,597 --> 00:43:19,934
[Man] I personally
like the view.
851
00:43:20,034 --> 00:43:22,602
Especially in the evening.
852
00:43:22,702 --> 00:43:25,739
I can see the evening skyline.
853
00:43:25,839 --> 00:43:29,342
[Woman] I like this
Cocoon Tower's looks 'cause
854
00:43:29,443 --> 00:43:32,012
this tower is,
like, looks fashionable
855
00:43:32,112 --> 00:43:33,813
and so iconic.
856
00:43:35,448 --> 00:43:38,285
[Jay] It's as much art
as it is architecture,
857
00:43:38,385 --> 00:43:42,723
adding something truly unique
to the built-up Tokyo skyline--
858
00:43:42,823 --> 00:43:45,125
an extraordinary cocoon shape
859
00:43:45,225 --> 00:43:49,596
that is worthy of all
the challenges the team faced.
860
00:43:50,898 --> 00:43:52,632
[Dr. Mabry] Projects
that are this elaborate,
861
00:43:52,733 --> 00:43:55,268
this complicated,
862
00:43:55,368 --> 00:43:56,437
are rare.
863
00:43:56,570 --> 00:43:58,238
That's what makes them exciting.
864
00:43:58,371 --> 00:44:05,312
[music]
865
00:44:07,080 --> 00:44:19,092
[music]
866
00:44:34,141 --> 00:44:36,443
♪ MTV ♪