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Narrator: In south korea,

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         This elite team
       of marine engineers

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          Is embarking
      on an epic endeavor.

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                     ♪

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   They're attempting to build
   the biggest container ship

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          In the world.

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 Stretching over 1,300 feet long

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     And capable of carrying
        a colossal 23,000

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      Shipping containers,

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  They are pushing to complete
   this record-breaking vessel

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       In just 12 months.

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     To build this behemoth,

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The team must battle
        massive loads...

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           [ laughs ]

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            Narrator:
    ...Terrifying heights...

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   ...And punishing deadlines.

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   This ship ranks in a league

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          Of ambitious
     new engineering wonders

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    That are bigger, faster,

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    Taller, and more advanced

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          Than anything
    ever constructed before.

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 This is the inside story of the
     extraordinary challenge

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    Of building these giants.

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                     ♪

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--<font color="
www.Vitac.Com

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Captions paid for by
discovery communications

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♪

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Narrator: Every year,
over 5,000 giant ships

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Cross the world's oceans,

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Stacked high
with containers full of goods.

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These monster vessels
transport everything

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From sports cars
and computers

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To soft toys
and refrigerated foods.

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  Now global shipping giant msc

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  Is embarking on an ambitious
        $1.8 billion plan

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   To build a brand-new breed
         of super ship.

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  At the company's headquarters
       in sorrento, Italy,

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 Giuseppe gargiulo is in charge
          of overseeing

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        The construction
 of this fleet of mammoth ships.

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   There are very good reasons
            to build

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       This revolutionary
         new mega-fleet.

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     Vessels will be cheaper
and more efficient to operate.

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                     ♪

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    This is the colossal ship
      the team must build.

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    Measuring over 1,300 feet
           in length,

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        It is longer than
      an aircraft carrier.

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   55,000 tons of metal panel
        make up its hull.

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         A single, giant
     34-foot-wide propeller

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   Thrusts the ship forwards.

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       This is powered by
 a three-story, 2,700-ton engine

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   That produces a staggering
       101,000 horsepower.

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A revolutionary stacking system
       supports containers

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       Over 100 feet high
         above the deck.

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        It will transport
       23,000 containers,

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      The most ever carried
          by one ship.

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    Building a ship this big
    will be a huge challenge.

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    The vessel's massive hull

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      Will push the limits
     of marine construction.

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     This fleet will include
       11 ships in total.

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   The first of this new breed
          of mega-ship

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Will be called the msc gulsun,
        meaning to smile.

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   This is how they'll do it.

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                     ♪

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   Engineers plan to construct
  the colossal ship in sections

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    Which they weld together,

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       Expanding the ship
         piece by piece.

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                     ♪

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  Next, they lift in the giant
        2,700-ton engine.

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    It's too large to install
          in one piece,

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        So they split it
        into four parts,

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 Then bolt it back together once
it's positioned within the ship.

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  The team attaches the mighty
        34-foot propeller

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        To the prop shaft
        with a metal cap.

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    Finally, they bolt on 27
   50-foot-high steel supports

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      To hold up the ship's
  13-high stack of containers.

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      With these in place,
   the largest container ship

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     The world has ever seen
      is ready to set sail.

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                     ♪

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To undertake this mammoth build,

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 Giuseppe's team is working with
marine engineers in south korea.

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   This shipyard on the island
            of geoje

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 Is one of the largest maritime
construction sites in the world.

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                     ♪

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    It sprawls across an area
         of 988 acres...

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                     ♪

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    ...Employs 10,000 staff,

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      And even has its own
          bus service.

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   The team here has to build
     the gigantic msc gulsun

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        In just one year.

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                     ♪

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       Work starts inside
this cavernous

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  410,000-square-foot workshop.

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     The team build the ship
         piece by piece

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  Out of 300 enormous sections
         called blocks.

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   To make these, their first
   challenge is to create vast

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          72-by-26-foot
    rectangular steel sheets.

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           Overseeing
  the assembly is jim man kim.

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   He starts with the largest
     steel sheets available.

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      But to make this side
    of the first giant block,

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         They must weld
four sheets together.

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    To do this marathon job,
          mr. Kim uses

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 A robotic submerged arc welder.

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                     ♪

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   It operates 30 times faster
      than a human worker.

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     The machine feeds wire
         into the joint,

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  Then uses an electric current

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     To superheat the metal,
           melting it.

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This forms an ultra-strong bond.

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           Yeah, so...

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                     ♪

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            Narrator:
     The welds are complete.

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This sheet of steel is now
in one huge 72-by-26-foot piece.

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                     ♪

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             Next...

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         Kim's team uses
  the expansive sheet of metal

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        To form a block.

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  Once complete, they transport
   the block to the quayside,

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   Where they weld it together
     with four other blocks

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   Like a giant metal jigsaw.

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  This is called a mega block,
  a colossal slice of the ship.

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 Workers then lower the 67 mega
    blocks into the dry dock,

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Starting with its keel.

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 They must place this mega block
  in exactly the right position

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      To make sure the rest
      of the ship is true.

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                     ♪

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  It takes 5 months to complete
      the first mega block.

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  It weighs a massive 923 tons.

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    Now the team must move it
          to the dock,

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00:09:17,824 --> 00:09:20,625
    Where they will assemble
       all 67 mega blocks

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     That make up the ship.

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    But it's over 1,500 feet
      from its destination.

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This perilous journey will test
    both humans and machines.

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                     ♪

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 Narrator: At this mega shipyard
         in south korea,

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      Workers are in a race

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      To build the world's
     biggest container ship.

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   They've completed the first
    923-ton steel mega block

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00:10:01,268 --> 00:10:04,836
       That will form part
       of the ship's hull.

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00:10:04,838 --> 00:10:09,407
   Now they must transport it
         over 1,500 feet

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00:10:09,409 --> 00:10:13,478
     And lower it into this
        enormous dry dock

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        Where the vessel
will be assembled.

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                     ♪

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    An ordinary crane stands
       no chance of moving

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00:10:24,057 --> 00:10:27,626
And lifting such a massive load,

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00:10:27,628 --> 00:10:31,563
   So they plan to use this --

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00:10:31,565 --> 00:10:35,900
    The goliath gantry crane.

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     It soars 300 feet high

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    And is capable of lifting

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00:10:41,207 --> 00:10:44,976
        And transporting
       almost 1,000 tons.

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      The man in charge of
      this colossal machine

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00:10:49,883 --> 00:10:51,383
        Is chang-ho baek.

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00:10:51,385 --> 00:10:52,917
           [ beeping ]

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      He works 80 floors up
  from this office in the sky,

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And takes great pride
    in his role at the yard.

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00:11:08,869 --> 00:11:12,871
    Given mr. Baek's 25 years
         of experience,

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00:11:12,873 --> 00:11:17,108
  He understands the gravity of
lifting such a heavy mega block.

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    16 cables secure the keel
          to the crane.

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        [ speaks korean ]

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            Narrator:
     They soon have liftoff.

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00:11:36,063 --> 00:11:38,997
          [ whirring ]

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00:11:41,301 --> 00:11:44,102
   Mr. Baek's crane has wheels
       that run on tracks

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00:11:44,104 --> 00:11:45,904
     That line the dockside.

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00:11:48,909 --> 00:11:51,476
  But guiding this giant block

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   Through the bustling people
and machinery

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00:11:54,581 --> 00:11:57,849
      To reach the dry dock
         won't be easy.

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00:12:07,427 --> 00:12:09,627
          It will take
       mr. Baek 30 minutes

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00:12:09,629 --> 00:12:12,630
  To slowly move the mega block
         into position.

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00:12:14,267 --> 00:12:17,635
          Halfway into
     the 1,500-foot journey,

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00:12:17,637 --> 00:12:19,871
      He runs into trouble.

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00:12:19,873 --> 00:12:21,573
   [ beeping, alarm wailing ]

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00:12:21,575 --> 00:12:23,908
     [ murmurs ]

172
00:12:26,313 --> 00:12:29,314
 Narrator: This stationary crane
        blocks his path.

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00:12:31,184 --> 00:12:35,286
   He needs to carefully raise
       and slide the block

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00:12:35,288 --> 00:12:37,722
         To maneuver it
      around this obstacle.

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00:12:37,724 --> 00:12:41,092
♪

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00:12:41,094 --> 00:12:44,229
        It takes mr. Baek
     five precarious minutes

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00:12:44,231 --> 00:12:47,198
       To slalom the block
  through the obstacle course.

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00:12:47,200 --> 00:12:50,969
                     ♪

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00:12:57,477 --> 00:13:01,179
  The mega block hovers 50 feet
       above the drop zone

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00:13:01,181 --> 00:13:03,481
     On the dry dock floor.

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00:13:03,483 --> 00:13:08,520
 Now mr. Baek faces the toughest
    stage of the whole move.

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00:13:08,522 --> 00:13:11,656
          He must lower
  the 200-foot-wide block down

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00:13:11,658 --> 00:13:15,660
           So it lands
  in precisely the right spot.

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00:13:15,662 --> 00:13:18,696
       Getting this wrong
     could misalign the rest

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00:13:18,698 --> 00:13:21,833
Of the nearly
      1,300-foot-long ship.

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00:13:26,506 --> 00:13:30,175
    The team down in the dock
   must act as mr. Baek's eyes

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00:13:30,177 --> 00:13:32,544
        On the ground...

188
00:13:32,546 --> 00:13:35,513
        [ speaks korean ]
  ...Using radios to guide him

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00:13:35,515 --> 00:13:39,150
       So the block lands
   smoothly on these supports.

190
00:13:39,152 --> 00:13:41,586
                     ♪

191
00:13:41,588 --> 00:13:43,254
         [ metal thuds ]

192
00:13:43,256 --> 00:13:45,557
 They hit the target perfectly.

193
00:14:05,745 --> 00:14:07,579
      It's a big milestone.

194
00:14:07,581 --> 00:14:10,481
       [ speaking korean ]

195
00:14:10,483 --> 00:14:12,617
          [ applause ]

196
00:14:12,619 --> 00:14:15,753
   But time is of the essence.

197
00:14:15,755 --> 00:14:18,823
   In 12 weeks, this dry dock
will be flooded

198
00:14:18,825 --> 00:14:22,227
         With more than
  150 million gallons of water,

199
00:14:22,229 --> 00:14:26,364
 And the ship must be watertight
       and ready to float.

200
00:14:29,069 --> 00:14:32,136
        This is the plan
for the next stage of the build.

201
00:14:34,341 --> 00:14:37,842
      With the 67 pre-built
      mega blocks in place,

202
00:14:37,844 --> 00:14:39,677
            The team
    will weld them together.

203
00:14:39,679 --> 00:14:41,613
          [ crackling ]

204
00:14:41,615 --> 00:14:43,281
            [ thud ]

205
00:14:43,283 --> 00:14:46,851
     They'll carefully lift
  each mega block into position

206
00:14:46,853 --> 00:14:50,421
       And then fuse them
      together one by one.

207
00:14:52,692 --> 00:14:55,760
The ship grows section
          by section...

208
00:14:55,762 --> 00:14:59,130
     [ clanking, crackling ]

209
00:14:59,132 --> 00:15:02,867
  ...Until the gargantuan hull
          is complete.

210
00:15:05,906 --> 00:15:13,278
                     ♪

211
00:15:13,280 --> 00:15:16,180
        It takes 4 weeks
    for the team to assemble

212
00:15:16,182 --> 00:15:19,717
   30 of the mega blocks that
 make up the body of the vessel.

213
00:15:21,254 --> 00:15:24,289
      Now, halfway through
       the yearlong build,

214
00:15:24,291 --> 00:15:29,027
   Hull supervisor duk-gun kim
       works with dy yang

215
00:15:29,029 --> 00:15:31,429
      To undertake a series
       of critical checks

216
00:15:31,431 --> 00:15:36,267
   On a vital part of the ship
called the ballast tanks.

217
00:15:36,269 --> 00:15:40,939
  Surprisingly, these sections
 of the hull must keep water in

218
00:15:40,941 --> 00:15:43,374
   Instead of keeping it out.

219
00:15:53,954 --> 00:15:57,255
 The ballast tanks are essential
       for this giant ship

220
00:15:57,257 --> 00:15:59,757
   To remain upright at port.

221
00:15:59,759 --> 00:16:04,362
                     ♪

222
00:16:04,364 --> 00:16:08,633
  Container ships usually visit
 several ports on each journey,

223
00:16:08,635 --> 00:16:13,638
 Loading and unloading only part
  of their cargo at each stop.

224
00:16:13,640 --> 00:16:17,675
  This can make the load uneven
     and unbalance the ship.

225
00:16:17,677 --> 00:16:20,745
      The 34 ballast tanks
     inside the ship's hull

226
00:16:20,747 --> 00:16:24,849
Are designed
  to counteract this disaster.

227
00:16:24,851 --> 00:16:26,918
  As the ship becomes unstable,

228
00:16:26,920 --> 00:16:30,254
     A pump transfers water
 between the vast ballast tanks

229
00:16:30,256 --> 00:16:32,724
   Positioned on either side.

230
00:16:32,726 --> 00:16:34,959
     The weight of the water
           counteracts

231
00:16:34,961 --> 00:16:37,228
        The uneven weight
       of the containers,

232
00:16:37,230 --> 00:16:39,764
     Keeping the ship level.

233
00:16:39,766 --> 00:16:43,067
      This ingenious system
   frees dock workers to load

234
00:16:43,069 --> 00:16:47,638
        And unload cargo
   without capsizing the ship.

235
00:16:47,640 --> 00:16:50,008
   At least, that's the plan.

236
00:16:50,010 --> 00:16:53,678
                     ♪

237
00:16:55,415 --> 00:16:58,549
Now they have to turn it
         into a reality.

238
00:17:07,427 --> 00:17:12,296
     Any faults could cause
   this mammoth ship to sink.

239
00:17:12,298 --> 00:17:14,132
                     ♪

240
00:17:24,844 --> 00:17:26,044
                     ♪

241
00:17:26,046 --> 00:17:28,646
    Narrator: In south korea,
       a team of engineers

242
00:17:28,648 --> 00:17:33,818
     Is building the biggest
  container ship in the world.

243
00:17:33,820 --> 00:17:36,687
        Hull supervisors
       dg kim and dy yang

244
00:17:36,689 --> 00:17:39,724
         Are making sure
     that the ballast tanks,

245
00:17:39,726 --> 00:17:41,192
    Vast containers for water

246
00:17:41,194 --> 00:17:44,962
    That stabilize the ship,
        are sealed tight.

247
00:17:44,964 --> 00:17:49,700
To do this, they perform
  a simple but effective test.

248
00:17:49,702 --> 00:17:53,805
    They pump pressurized air
      into a finished tank

249
00:17:53,807 --> 00:17:57,475
       And cover the welds
         in soapy water.

250
00:18:05,385 --> 00:18:07,585
                     ♪

251
00:18:07,587 --> 00:18:09,654
 Any air escaping through holes

252
00:18:09,656 --> 00:18:12,990
        Would cause large
  expanding bubbles to appear.

253
00:18:23,870 --> 00:18:28,806
   They check every single one
 of the 95-foot-long tank welds.

254
00:18:35,615 --> 00:18:38,282
                     ♪

255
00:18:38,284 --> 00:18:40,618
    This tank is sealed tight

256
00:18:40,620 --> 00:18:43,821
        And ready to help
      the ship stay afloat.

257
00:18:43,823 --> 00:18:47,758
But with 33 more tanks to check,
          kim and yang

258
00:18:47,760 --> 00:18:50,094
      Still have a big job
         ahead of them.

259
00:18:50,096 --> 00:18:57,401
                     ♪

260
00:18:57,403 --> 00:19:00,304
          It's 7 months
    into the yearlong build.

261
00:19:04,577 --> 00:19:07,645
      All 67 mega blocks of
         the ship's hull

262
00:19:07,647 --> 00:19:09,547
      Are now welded tight.

263
00:19:12,418 --> 00:19:17,755
      A ship this big needs
    a power source to match,

264
00:19:17,757 --> 00:19:19,924
   And the msc gulsun's engine

265
00:19:19,926 --> 00:19:22,760
      Is one of the biggest
          in the world.

266
00:19:22,762 --> 00:19:25,863
                     ♪

267
00:19:25,865 --> 00:19:30,268
       This is the man g95
         diesel engine.

268
00:19:32,338 --> 00:19:37,241
This enormous engine has
  more than 100,000 horsepower,

269
00:19:37,243 --> 00:19:41,979
   The equivalent to over 100
        nascar race cars.

270
00:19:43,283 --> 00:19:47,051
                     ♪

271
00:19:47,053 --> 00:19:50,221
  The ship's engine is a giant
        in its own right,

272
00:19:50,223 --> 00:19:53,424
      Weighing 2,700 tons.

273
00:19:55,595 --> 00:19:59,830
   It's so big, workers can't
     install it all at once.

274
00:20:02,168 --> 00:20:03,668
     To solve this problem,

275
00:20:03,670 --> 00:20:09,106
  Engineers must break it down
  into four interlocking parts.

276
00:20:09,108 --> 00:20:14,111
  They lift in the two sections
 that make up the engine's base.

277
00:20:14,113 --> 00:20:18,449
       Next, they install
the huge middle section

278
00:20:18,451 --> 00:20:20,051
   That contains the frame box

279
00:20:20,053 --> 00:20:22,620
         That keeps the
  engine's components together.

280
00:20:24,390 --> 00:20:29,160
       Finally, they bolt
       on the top section,

281
00:20:29,162 --> 00:20:33,364
 Capping the engine's supersized
     17-foot-long cylinders.

282
00:20:35,368 --> 00:20:39,670
     They must connect each
         part perfectly.

283
00:20:39,672 --> 00:20:44,141
Even a slight misalignment could
   create dangerous vibrations

284
00:20:44,143 --> 00:20:45,843
   When the engine is running.

285
00:20:49,115 --> 00:20:56,387
                     ♪

286
00:20:56,389 --> 00:21:00,091
  It's the day of the engine's
            big move.

287
00:21:00,093 --> 00:21:05,029
In charge of preparations is
engine supervisor jung-woo shin.

288
00:21:12,772 --> 00:21:15,306
                     ♪

289
00:21:15,308 --> 00:21:18,643
      First, workers place
           the 550-ton

290
00:21:18,645 --> 00:21:21,712
          Rear section
       of the engine base,

291
00:21:21,714 --> 00:21:24,649
          Then quickly
   install the front section.

292
00:21:24,651 --> 00:21:29,053
                     ♪

293
00:21:29,055 --> 00:21:31,122
          [ rattling ]

294
00:21:31,124 --> 00:21:34,892
     They lock it together,
   forming a solid foundation.

295
00:21:34,894 --> 00:21:38,396
                     ♪

296
00:21:40,266 --> 00:21:42,800
                     ♪

297
00:21:42,802 --> 00:21:45,736
 But the next section of engine

298
00:21:45,738 --> 00:21:48,139
 Is twice the size of the last.

299
00:21:49,842 --> 00:21:52,209
         And in a build
this complicated,

300
00:21:52,211 --> 00:21:54,545
       Every inch counts.

301
00:22:01,954 --> 00:22:05,356
     [ shouting in korean ]

302
00:22:05,358 --> 00:22:07,224
           [ clangs ]

303
00:22:18,938 --> 00:22:22,039
                     ♪

304
00:22:22,041 --> 00:22:24,709
   Narrator: At this shipyard
         in south korea,

305
00:22:24,711 --> 00:22:26,677
   Workers are racing to build

306
00:22:26,679 --> 00:22:31,182
   The largest container ship
          in the world.

307
00:22:31,184 --> 00:22:36,120
  They've moved the base of its
 2,700-ton engine into position.

308
00:22:37,523 --> 00:22:39,123
      Today, they must lift

309
00:22:39,125 --> 00:22:41,692
          The enormous
  middle section of the engine.

310
00:22:41,694 --> 00:22:44,028
                     ♪

311
00:22:44,030 --> 00:22:46,664
          7:30 a.M. --

312
00:22:46,666 --> 00:22:49,333
Before the rigors of
   ship-building can start...

313
00:22:49,335 --> 00:22:51,936
       [ speaking korean ]

314
00:22:51,938 --> 00:22:53,771
          [ all clap ]

315
00:22:53,773 --> 00:22:57,074
 ...The yard workers participate
      in morning exercises.

316
00:22:58,144 --> 00:22:59,410
       [ speaking korean ]

317
00:23:09,355 --> 00:23:12,356
       [ speaking korean,
           clapping ]

318
00:23:20,767 --> 00:23:28,038
                     ♪

319
00:23:28,040 --> 00:23:29,940
            Narrator:
     This section of engine

320
00:23:29,942 --> 00:23:34,979
         Is 75 feet long
 and must be moved in one piece.

321
00:23:34,981 --> 00:23:36,547
   It will be a tight squeeze

322
00:23:36,549 --> 00:23:39,817
      Guiding this enormous
       engine section down

323
00:23:39,819 --> 00:23:42,253
Through the interior
          of the ship,

324
00:23:42,255 --> 00:23:45,723
    Where builders are still
  constructing the engine room.

325
00:23:57,203 --> 00:24:02,339
 The massive engine glides down
   into the belly of the ship,

326
00:24:02,341 --> 00:24:05,376
  With just inches to spare on
          either side.

327
00:24:05,378 --> 00:24:09,413
                     ♪

328
00:24:09,415 --> 00:24:12,316
  But 10 feet from touchdown...

329
00:24:12,318 --> 00:24:17,922
     [ shouting in korean ]

330
00:24:17,924 --> 00:24:20,324
 Narrator: ...These scaffolding
          support bars

331
00:24:20,326 --> 00:24:23,160
   Block the engine's descent.

332
00:24:23,162 --> 00:24:29,066
   The 595-ton middle section
       is stuck in midair.

333
00:24:29,068 --> 00:24:31,402
      If they try to force
it down now,

334
00:24:31,404 --> 00:24:35,706
  They could damage the engine,
  putting the build back weeks.

335
00:24:35,708 --> 00:24:37,074
      [ man speaks korean ]

336
00:24:50,122 --> 00:24:53,424
   Narrator: Workers scramble
     to remove the blockage.

337
00:24:53,426 --> 00:24:56,494
  They cut the scaffolding bars

338
00:24:56,496 --> 00:25:00,264
       And bend them away
     from the engine's path.

339
00:25:00,266 --> 00:25:02,466
      The move is back on.

340
00:25:02,468 --> 00:25:08,839
                     ♪

341
00:25:08,841 --> 00:25:11,075
         Down it goes...

342
00:25:11,077 --> 00:25:13,611
                     ♪

343
00:25:13,613 --> 00:25:14,879
           [ clangs ]

344
00:25:14,881 --> 00:25:17,648
    ...Safe and in one piece.

345
00:25:22,955 --> 00:25:26,891
               ♪

346
00:25:26,893 --> 00:25:30,928
  Installing the ship's engine
is a big milestone for the team.

347
00:25:30,930 --> 00:25:34,765
                     ♪

348
00:25:36,802 --> 00:25:39,803
                     ♪

349
00:25:39,805 --> 00:25:43,807
  But the engine alone will not
    make this mega ship move.

350
00:25:43,809 --> 00:25:48,979
The linchpin of any great vessel
        is its propeller.

351
00:25:48,981 --> 00:25:52,850
 The propeller on this ship will
 be one of the world's biggest.

352
00:25:52,852 --> 00:25:56,554
   Its design is overseen here
       in sorrento, Italy.

353
00:26:07,333 --> 00:26:09,033
       The more efficient
         the propeller,

354
00:26:09,035 --> 00:26:12,336
The less fuel the ship will use.

355
00:26:12,338 --> 00:26:14,505
   But with such a big engine
           turning it,

356
00:26:14,507 --> 00:26:17,441
The propeller must be tough
       enough to withstand

357
00:26:17,443 --> 00:26:19,276
       Monumental forces.

358
00:26:21,013 --> 00:26:24,682
                     ♪

359
00:26:24,684 --> 00:26:29,687
  Giuseppe's team has designed
   a totally unique propeller.

360
00:26:29,689 --> 00:26:33,524
   He has given it six blades
instead of the conventional five

361
00:26:33,526 --> 00:26:37,161
 To reduce the amount of stress
   on each blade as it turns.

362
00:26:37,163 --> 00:26:41,165
     [ creaking, rumbling ]

363
00:26:41,167 --> 00:26:45,069
   This means he can lengthen
      each blade to 17 feet

364
00:26:45,071 --> 00:26:49,506
      To make the propeller
       much more powerful.

365
00:26:49,508 --> 00:26:52,476
     Finally, they fine-tune
the shape,

366
00:26:52,478 --> 00:26:55,646
      Thickness, and angle
         of the blades,

367
00:26:55,648 --> 00:26:59,183
   Maximizing their efficiency
           and power.

368
00:26:59,185 --> 00:27:02,586
  This one-of-a-kind propeller
  will quickly and efficiently

369
00:27:02,588 --> 00:27:06,490
 Drive the 70,000-ton mega ship
        around the world

370
00:27:06,492 --> 00:27:08,959
     For the next 30 years.

371
00:27:13,065 --> 00:27:18,235
 Building such a huge propeller
     will be no simple task.

372
00:27:18,237 --> 00:27:22,039
 Giuseppe works with the world's
   leading propeller foundry,

373
00:27:22,041 --> 00:27:26,944
    Mecklenburger metallguss,
           in germany.

374
00:27:26,946 --> 00:27:30,014
     Their managing director
is lars greitsch.

375
00:27:40,092 --> 00:27:42,893
      Lars' team will cast
      this giant propeller

376
00:27:42,895 --> 00:27:45,162
 As one massive piece of metal.

377
00:27:50,503 --> 00:27:54,438
     To build this $880,000
           propeller,

378
00:27:54,440 --> 00:27:59,443
 Lars' team must first fabricate
   this 40-foot concrete mold.

379
00:27:59,445 --> 00:28:02,312
      Next, the team takes
         an entire night

380
00:28:02,314 --> 00:28:05,983
  To heat a mixture of copper,
   aluminum, nickel, and iron

381
00:28:05,985 --> 00:28:08,919
        To 2,000 degrees.

382
00:28:08,921 --> 00:28:11,221
       This makes bronze.

383
00:28:11,223 --> 00:28:14,091
    The metal alloy will make
      the propeller strong

384
00:28:14,093 --> 00:28:17,794
          And resistant
to corrosive seawater.

385
00:28:17,796 --> 00:28:19,663
      They move the bronze
         into position,

386
00:28:19,665 --> 00:28:23,267
     Ready for the big pour
     into the concrete mold.

387
00:28:23,269 --> 00:28:27,471
This is the most critical moment
       for any propeller.

388
00:28:46,425 --> 00:28:47,925
      Narrator: In germany,

389
00:28:47,927 --> 00:28:50,928
      Engineers are casting
      the mammoth propeller

390
00:28:50,930 --> 00:28:54,198
   That will power the biggest
  container ship in the world.

391
00:28:54,200 --> 00:29:00,070
                     ♪

392
00:29:00,072 --> 00:29:05,943
  Lars' team must fill the mold
     in one continuous pour.

393
00:29:05,945 --> 00:29:07,745
   If they stop at any point,

394
00:29:07,747 --> 00:29:10,948
The impurities floating on top
      of the molten bronze

395
00:29:10,950 --> 00:29:13,984
      Could become trapped
in the interior of the propeller

396
00:29:13,986 --> 00:29:16,286
 And cause structural weakness.

397
00:29:31,370 --> 00:29:35,372
                     ♪

398
00:29:35,374 --> 00:29:38,876
       It takes 15 minutes
        to fill the mold

399
00:29:38,878 --> 00:29:42,212
 In one intensive nonstop pour.

400
00:29:45,151 --> 00:29:48,852
 The team must now wait one week
     for the metal to cool.

401
00:29:53,959 --> 00:29:56,860
                     ♪

402
00:29:56,862 --> 00:30:01,799
  The raw cast propeller spans
      a vast 34 feet wide.

403
00:30:04,036 --> 00:30:06,236
     The team must now shape
           its blades

404
00:30:06,238 --> 00:30:09,072
       To precisely match
giuseppe's designs.

405
00:30:10,709 --> 00:30:12,943
 To do this, they use a special

406
00:30:12,945 --> 00:30:15,045
        Robotically aided
        grinding machine.

407
00:30:15,047 --> 00:30:18,515
          [ whirring ]

408
00:30:35,367 --> 00:30:39,136
                     ♪

409
00:30:39,138 --> 00:30:43,974
     It takes weeks to shape
     and polish the blades.

410
00:30:43,976 --> 00:30:46,643
         They then ship
     the completed propeller

411
00:30:46,645 --> 00:30:50,848
      More than 5,000 miles
         to south korea.

412
00:30:50,850 --> 00:30:57,921
                     ♪

413
00:30:57,923 --> 00:31:02,459
   With the massive propeller
on-site, the team in south korea

414
00:31:02,461 --> 00:31:06,363
      Must now position it
   onto the ship's prop shaft.

415
00:31:06,365 --> 00:31:08,565
With a tolerance of just
      a fraction of an inch

416
00:31:08,567 --> 00:31:09,967
          To work with,

417
00:31:09,969 --> 00:31:13,136
      This is an incredibly
     challenging operation.

418
00:31:15,241 --> 00:31:19,543
      To install the giant
       129-ton propeller,

419
00:31:19,545 --> 00:31:24,681
       The team must first
carefully crane it into position

420
00:31:24,683 --> 00:31:30,120
And slide the prop shaft through
   the hole in the propeller.

421
00:31:30,122 --> 00:31:33,290
   Engineers then use powerful
         hydraulic pumps

422
00:31:33,292 --> 00:31:37,327
   To force the propeller even
 further back towards the ship.

423
00:31:37,329 --> 00:31:41,131
    The fit is so tight that
the force of friction alone

424
00:31:41,133 --> 00:31:43,500
       Locks the propeller
           into place.

425
00:31:45,237 --> 00:31:47,938
   Finally, with the propeller
            secured,

426
00:31:47,940 --> 00:31:52,876
  The team seals it in position
         with a 2.7-ton,

427
00:31:52,878 --> 00:31:55,345
      6 1/2-foot wide cap.

428
00:31:59,251 --> 00:32:03,287
    With the propeller safely
          on the shaft,

429
00:32:03,289 --> 00:32:07,324
    Now the team must lock it
       tightly into place.

430
00:32:07,326 --> 00:32:10,027
      This is a key moment
         in the build...

431
00:32:10,029 --> 00:32:11,361
   Twenty-one.
           Twenty-one.

432
00:32:11,363 --> 00:32:12,930
     Twenty-one.

433
00:32:12,932 --> 00:32:17,334
 Narrator: ...That's overseen by
expert engineer jessica brun.

434
00:32:24,310 --> 00:32:26,910
        Jessica works for
  an international organization

435
00:32:26,912 --> 00:32:31,281
    That monitors the quality
     of ship manufacturing.

436
00:32:31,283 --> 00:32:35,385
    It's her job to sign off
  on vital parts of the build.

437
00:32:36,689 --> 00:32:38,722
       [ speaking korean ]

438
00:32:38,724 --> 00:32:40,290
            Narrator:
   This record-breaking vessel

439
00:32:40,292 --> 00:32:43,460
    Can't leave the shipyard
   without jessica's approval.

440
00:32:51,337 --> 00:32:52,502
           [ laughs ]

441
00:32:55,741 --> 00:32:58,775
  Narrator: The team uses giant
         hydraulic pumps

442
00:32:58,777 --> 00:33:01,511
      To push the propeller
          up the shaft.

443
00:33:07,920 --> 00:33:11,788
Once the propeller is locked,
 it will not move on the shaft.

444
00:33:15,694 --> 00:33:19,463
    They use a micrometer to
 check the propeller's position.

445
00:33:19,465 --> 00:33:21,431
   ...81, huh?
                     Yeah, yeah.

446
00:33:21,433 --> 00:33:22,833
      ...81.
                           Yeah.

447
00:33:25,871 --> 00:33:28,605
      Narrator: The mighty
        129-ton propeller

448
00:33:28,607 --> 00:33:33,744
         Is in position
        and locked tight.

449
00:33:33,746 --> 00:33:36,780
     Jessica can sign it off
          as seaworthy.

450
00:33:44,923 --> 00:33:50,427
                     ♪

451
00:33:50,429 --> 00:33:52,996
    Narrator: With the engine
   and propeller in position,

452
00:33:52,998 --> 00:33:57,000
The team faces one final
  major construction challenge.

453
00:33:59,104 --> 00:34:01,571
   They must build the complex
         system of beams

454
00:34:01,573 --> 00:34:05,575
     And supports that holds
   the containers in position.

455
00:34:05,577 --> 00:34:10,047
                     ♪

456
00:34:10,049 --> 00:34:12,616
         This mega ship
   will hold a record-breaking

457
00:34:12,618 --> 00:34:14,818
       23,000 containers.

458
00:34:14,820 --> 00:34:18,355
                     ♪

459
00:34:18,357 --> 00:34:20,791
           Below deck,
       the ship will carry

460
00:34:20,793 --> 00:34:25,295
    9,788 in stacks 12 high.

461
00:34:25,297 --> 00:34:31,868
                     ♪

462
00:34:31,870 --> 00:34:34,671
     But the real difference
        lies above deck.

463
00:34:37,810 --> 00:34:40,977
Here, superstrong steel frames

464
00:34:40,979 --> 00:34:45,215
     Called lashing bridges
         span the hull.

465
00:34:45,217 --> 00:34:48,585
   These have special fixtures
       called lashing rods

466
00:34:48,587 --> 00:34:52,989
 To secure stacks of containers
   that soar 13 stories high.

467
00:34:52,991 --> 00:34:55,025
          [ creaking ]

468
00:34:55,027 --> 00:34:57,327
                     ♪

469
00:34:57,329 --> 00:35:01,765
 That's two stories taller than
 on most other container ships.

470
00:35:01,767 --> 00:35:08,371
                     ♪

471
00:35:08,373 --> 00:35:11,241
      Today, a new delivery
       of lashing bridges

472
00:35:11,243 --> 00:35:15,078
         Arrives on-site
 from the factory 25 miles away.

473
00:35:16,715 --> 00:35:21,351
The msc gulsun will have 27 rows
of lashing bridges.

474
00:35:22,988 --> 00:35:27,524
      Each weighs 132 tons.

475
00:35:27,526 --> 00:35:29,893
      The team must install
          these bridges

476
00:35:29,895 --> 00:35:32,896
 Onto a 100-foot-high platform.

477
00:35:52,317 --> 00:35:56,786
                     ♪

478
00:35:56,788 --> 00:35:58,755
    Narrator: In south korea,

479
00:35:58,757 --> 00:36:02,459
    Workers race to build the
 world's biggest container ship.

480
00:36:05,264 --> 00:36:10,400
   They've completed the hull
  and installed the propeller.

481
00:36:10,402 --> 00:36:12,835
       Now, they must fit
       the lashing bridges

482
00:36:12,837 --> 00:36:16,706
   That secure the containers
          to the ship.

483
00:36:16,708 --> 00:36:21,378
     They tower 50 feet tall
     and are 200 feet wide.

484
00:36:24,683 --> 00:36:29,519
Mr. Yong-wan chung is gearing up
 to install bridge number eight.

485
00:36:31,924 --> 00:36:34,457
     The team must stand on
      this narrow platform

486
00:36:34,459 --> 00:36:37,427
 To guide it down into position.

487
00:36:37,429 --> 00:36:40,864
  Any miscalculation could end
          in disaster.

488
00:36:49,808 --> 00:36:55,412
   So the team uses harnesses
  and clips on to safety lines.

489
00:36:55,414 --> 00:36:59,249
    The mighty 300-foot-high
      goliath gantry crane

490
00:36:59,251 --> 00:37:03,153
        Takes the weight
     of bridge number eight.

491
00:37:03,155 --> 00:37:06,423
     To make this precarious
 challenge even more difficult,

492
00:37:06,425 --> 00:37:10,026
       The team must guide
this 132-ton chunk of metal

493
00:37:10,028 --> 00:37:12,362
     Into position by hand.

494
00:37:16,368 --> 00:37:21,504
                     ♪

495
00:37:21,506 --> 00:37:23,707
   After a dizzying descent...

496
00:37:23,709 --> 00:37:29,312
                     ♪

497
00:37:29,314 --> 00:37:32,249
     ...The bridge is down.
           [ clanks ]

498
00:37:41,226 --> 00:37:44,794
                     ♪

499
00:37:44,796 --> 00:37:49,699
 Chung's team welds the lashing
         bridge in place

500
00:37:49,701 --> 00:37:52,736
         And secures it
   for the life of the vessel.

501
00:37:52,738 --> 00:37:56,039
                     ♪

502
00:37:56,041 --> 00:38:00,977
    After 12 weeks of intense
          construction,

503
00:38:00,979 --> 00:38:05,682
   The hull, engine, and deck
        are all complete.

504
00:38:05,684 --> 00:38:07,617
                     ♪

505
00:38:07,619 --> 00:38:11,721
Now the moment of truth
      for the build team --

506
00:38:11,723 --> 00:38:13,290
      Will the ship float?

507
00:38:15,260 --> 00:38:18,061
        The team plans to
  flood the dry dock with water

508
00:38:18,063 --> 00:38:22,832
          At 12:30 a.M.
      To launch the vessel.

509
00:38:22,834 --> 00:38:27,070
         As night falls,
     the tension is palpable

510
00:38:27,072 --> 00:38:30,674
      For vessel supervisor
        byump-cheol jung.

511
00:38:37,916 --> 00:38:39,416
           [ laughs ]

512
00:38:39,418 --> 00:38:42,652
                     ♪

513
00:38:42,654 --> 00:38:46,656
    Narrator: With water set
       to flood the dock,

514
00:38:46,658 --> 00:38:51,895
Every weld must be sealed tight,
 and the ship must be balanced,

515
00:38:51,897 --> 00:38:54,964
Or after nearly a year
        of grueling work,

516
00:38:54,966 --> 00:38:57,867
            This ship
   won't be deemed seaworthy.

517
00:39:00,339 --> 00:39:03,073
                     ♪

518
00:39:03,075 --> 00:39:04,841
   This is the crucial moment

519
00:39:04,843 --> 00:39:07,811
      They've been working
      towards for 3 months.

520
00:39:15,454 --> 00:39:19,789
                     ♪

521
00:39:19,791 --> 00:39:23,059
         The pumps open,

522
00:39:23,061 --> 00:39:24,594
     And the dry dock fills

523
00:39:24,596 --> 00:39:28,565
            With over
150 million gallons of seawater.

524
00:39:28,567 --> 00:39:31,000
                     ♪

525
00:39:31,002 --> 00:39:34,237
  With a nerve-racking wobble,

526
00:39:34,239 --> 00:39:36,940
        In just 4 hours,

527
00:39:36,942 --> 00:39:39,843
        The ship lifts up

528
00:39:39,845 --> 00:39:41,578
        Off its supports.

529
00:39:41,580 --> 00:39:47,650
♪

530
00:39:47,652 --> 00:39:55,158
                     ♪

531
00:39:55,160 --> 00:39:59,429
    Day breaks to reveal that
    the massive ship floats,

532
00:39:59,431 --> 00:40:02,031
      No leaks, no damage.

533
00:40:02,033 --> 00:40:04,667
                     ♪

534
00:40:04,669 --> 00:40:07,837
       It's a huge moment
      for the entire team.

535
00:40:10,675 --> 00:40:14,844
       After a long night,
   bc jung is tired but happy.

536
00:40:22,320 --> 00:40:25,121
        ...The floating.
           Actually...

537
00:40:28,860 --> 00:40:31,895
                     ♪

538
00:40:31,897 --> 00:40:35,732
    It takes a fleet of three
   tugboats to carefully guide

539
00:40:35,734 --> 00:40:39,269
       The 60,000-ton ship
       out of the dry dock

540
00:40:39,271 --> 00:40:43,973
To a special quay where the team
 can add the finishing touches.

541
00:40:48,213 --> 00:40:51,181
                     ♪

542
00:40:51,183 --> 00:40:55,118
     Over the next 4 months,
   the teams build and install

543
00:40:55,120 --> 00:40:57,887
      The ship's innovative
        exhaust system...

544
00:40:57,889 --> 00:40:59,622
                     ♪

545
00:40:59,624 --> 00:41:02,459
        ...The bridge...

546
00:41:02,461 --> 00:41:05,795
    The living accommodations
          for the crew,

547
00:41:05,797 --> 00:41:11,701
  And wire it up with more than
222 miles of electrical cabling.

548
00:41:11,703 --> 00:41:15,104
 They complete this work 12 days
       ahead of schedule.

549
00:41:15,106 --> 00:41:17,774
                     ♪

550
00:41:17,776 --> 00:41:20,009
    In just under 12 months,

551
00:41:20,011 --> 00:41:23,379
The team has built the world's
     largest container ship.

552
00:41:25,417 --> 00:41:26,616
   Hello, morning.
    How are you?

553
00:41:26,618 --> 00:41:29,686
 Giuseppe gargiulo has traveled
           from Italy

554
00:41:29,688 --> 00:41:32,889
 For a well-earned celebration,

555
00:41:32,891 --> 00:41:35,191
        And to officially
          name the ship

556
00:41:35,193 --> 00:41:39,529
         The msc gulsun,
       meaning "to smile."

557
00:41:43,702 --> 00:41:45,568
          [ applause ]

558
00:41:56,414 --> 00:41:59,516
            Narrator:
    The msc gulsun sets off,

559
00:41:59,518 --> 00:42:01,484
    Bound for eastern china,

560
00:42:01,486 --> 00:42:05,455
      Where it will receive
  its first load of containers,

561
00:42:05,457 --> 00:42:10,326
  Traveling more than 3 million
miles over her life span.

562
00:42:10,328 --> 00:42:12,395
  Ten more ships just like her

563
00:42:12,397 --> 00:42:14,631
        Will be delivered
        in the next year

564
00:42:14,633 --> 00:42:17,800
     Carrying over a quarter
     of a million containers

565
00:42:17,802 --> 00:42:19,736
          Between them,

566
00:42:19,738 --> 00:42:24,307
 Transporting the world's goods
   as efficiently as possible.