All language subtitles for Building.Giants.S05E01.1080p.WEB.h264-CBFM_track3_[eng]

[narrator]
Today, this elite team of
shipbuilders is embarking on

an extraordinary endeavor.

When she's built, she'll be
absolutely amazing.

They are racing to build
an astonishing vessel, one of

the largest and most advanced
cruise ships in the world.

This is a ship of mammoth
magnitude, constructed from

over 46,000 tons of steel.

It will carry almost
9,000 passengers and crew,

equipped with the world's
longest onboard dry slide,

and capable of running on

a groundbreaking new
fuel source.

There's a new prototype.

To build this seafaring
Goliath, the team must combine

time-honored tradition...

[man speaking French]

...with trailblazing
technology...

The amount of things to do
is unbelievable.

...and punishing deadlines.

This colossal cruise line ranks
in the league of ambitious new

engineering wonders
that are bigger, faster,

taller, and more advanced

than anything ever
constructed before.

This is the inside story
of the extraordinary challenge

of building these giants.

-[crumbling]
-[metal clank]

[metallic thudding]

Today in Saint-Nazaire, France,

an enormous team
of 3,000 shipbuilders

is starting construction
on the prototype

for a new class of colossal
cruise liner.

[Trevor] It is a massive ship.

It's one of the biggest
in the world.

We have 22 stories,

40,000 square meters of
public area.

It's a huge ship.

The new prototype is called
MSC World Europa.

Trevor Young leads the team
designing this giant.

This ship will push
a lot of boundaries,

from the interior design
and the guest experience,

but also the technical side.

This new class of ship will be
the largest and most advanced

vessel this cruise line
has ever built.

It features a brand-new
futuristic bow shape

to help it carve through waves.

And the vessel's ambitious
scale and innovation will

stretch the limits of cruise
ship design and construction.

We wanted this ship to be
the next level, or the next

generation of what we have
built in the past.

The inspiration was
"Blade Runner 2049,"

where everything is
high technology,

but also very organic
and not just uniform.

So when she's built,
she'll be absolutely amazing.

A high-tech vessel of this
magnitude doesn't come cheap.

The ship's owner is investing
over $1.3 billion to build this

ocean-going leviathan.

The cost of building this ship
is quite extraordinary when

you think about it --
it's over 1 billion euro.

It's a huge investment.

We have a huge team here in
London to actually design

and coordinate the build
of the vessel.

We have teams also in
the shipyard

where we're
building in France.

Overseeing
the ship's construction

is site director
Gaetano Rolando.

It falls to him to ensure
the vessel is built

and delivered on time.

I like my work from
the beginning of the project

until delivery because every day
is different.

Gaetano has been building
ships at this yard

for more than eight years.

But World Europa will be
the largest vessel he's ever

constructed and his biggest
challenge to date.

[Gaetano] Most important
is the totally different shape,

from the bow
to the aft.

This is the mammoth prototype
cruise ship Gaetano

and the team must build.

Measuring nearly
1,100 feet long

and weighing
almost 86,000 tons,

this vessel will be longer
than the Eiffel Tower

and seven times as heavy.

Propelling this Goliath will be
five 14-cylinder engines

powered by an innovative fuel
system known as LNG,

liquefied natural gas.

This is a first
for the company.

The ship is designed with
a ground-breaking

open-air shopping promenade
with panoramic ocean views.

On board, they plan to build
13 dining areas,

seven swimming pools,

and an opulent rear lounge,
complete with chandeliers,

to entertain the 6,762 guests
staying in 2,626 cabins.

This vast vessel will be

the largest and most
complex cruise ship

the team has ever
attempted to build.

[Gaetano]
From the technical point of
view, the energy efficiency,

to the design point of view,
is a different kind of ship.

We are here in Saint-Nazaire
to supervise each step,

from the beginning
until the end.

Gaetano and the team have just
36 months to build, test,

to deliver the gigantic vessel.

To recover some of the enormous
construction costs, tickets for

the maiden voyage
have gone on sale

before the vessel is complete.

[Trevor]
The demand has been
incredible, so we're super

excited that our passengers
feel as excited as we do about

this new vessel that
we're building.

Delaying the liner's maiden
voyage would be a disaster.

Pressure is on to ensure
the team finishes the work

on time and delivers
the ship as promised.

[Trevor]
Delivering the ship on time is
incredibly important for us,

because it gives confidence
also with our passengers that

everything is running smoothly.

Building this mammoth new ship

involves a number of
crucial challenges.

This is how Gaetano
and the shipyard will do it.

First, workers must cut, bend,
and weld over 46,000 tons of

steel into 59 massive sections
of ship called megablocks.

The megablocks
will fit together

to form the skeleton
of the ship.

Next, workers must install
two mammoth 343-ton tanks

into the bowels of the vessel

that will hold the ship's
liquefied-natural-gas fuel.

These will connect to
five 16-megawatt engines

that will power the ship.

Once afloat, the team must
complete the public spaces with

the shops, bars, and lounges.

Build, furnish,
and install the 2,626 cabins.

And when complete,
the team will need to load

386 tons of food and drink for
guests before setting sail.

Gaetano and the team will begin
transferring sheets of

bare steel into the 350,000
individual pieces that will

form the vessel's frame.

To do this, they use special
cutting machines that

fire jets of superheated gas,

called plasma,
through the steel.

This slices the metal with
millimeter precision.

[Gaetano]
It's like a puzzle, where each
pieces have their final

location, final position,
altogether forming

the big ship like this.

Each piece is then carefully
bent and molded into shape

using powerful presses.

This enables workers
to meticulously craft

the cruise ship's unique shape.

Next, engineers assemble
sections of the vessel in these

giant workshops.

They weld together
the freshly molded pieces

of steel into panels.

But Gaetano and the team
have a big problem.

It's a mammoth operation

to construct each
of the ship's 22 decks.

To build, wire up, and furnish
the vessel one layer at a time,

deck by deck,
would take years,

and the ship would miss
its crucial delivery date.

Every day we are running against
the schedule.

And every day
we are solving a lot of

problem together with the yard
in order to be on time.

To ensure they hit
their deadline, workers here

use an ingenious technique
to speed up construction.

The steel panels
are built upside down.

This allows workers
easy access to install

the ship's critical services,

including plumbing
and ventilation,

into the ceiling.

A vessel of this size requires
around 75 miles of

electrical cable

and over 90 miles of piping.

Next, workers need to join
the completed panels together

to form a megablock.

[soft metal clanking]

Once a steel panel is complete,
it is placed on top of another

and welded into position.

Each panel measures
one deck high,

and it takes around 20 panels
to form one megablock.

Once a megablock is complete,

workers use
the yard's giant gantry crane

to lift and flip
the megablock over,

turning it the correct way up.

The crane transfers
the finished megablock
to the dry dock...

[metal clanking]

...where it's carefully lowered
and welded into place.

It takes around nine weeks to
construct each one of

World Europa's 59 megablocks.

Using this megablock method,
the team can work

on multiple parts of the ship
at the same time,

which speeds up the build.

Each block is around
1,000, 1,300 tons,

so it's really megablocks.

But lifting these mammoth
megablocks requires some

mega equipment.

[majestic music builds
and fades]

In this vast shipyard in
Saint-Nazaire, France,

this team is
racing to construct
the $1.3 billion prototype

for a brand-new class
of cruise ship.

We have the biggest crane
in Europe, so the block

can be very big.

At 213 feet high,

and with a lifting capacity
of over 1,500 tons,

this giant gantry crane lifts,
flips, and moves the megablocks

with ease.

The entire shipyard
springs into action.

Megablock after megablock
is assembled, welded,

and lowered into position.

The length of
World Europa's enormous hull

starts to fill the dock.

After 10 months of
furious construction...

[beeping]

♪♪

...progress on the build
grinds to a halt.

The team can't add any more
megablocks until

the ship's innovative LNG
fuel tanks and equipment

are installed in the hull.

[soft piano music plays]

Large vessels like cruise ships
are traditionally fueled by

a form of diesel
or marine gas oil.

This new cruise ship
will be powered by
liquefied natural gas,

or LNG.

This is methane that is cleaned
of impurities and cooled to

around minus
256 degrees Fahrenheit.

This turns the gas
into a liquid,

which takes up 600 times
less space to transport,

meaning more fuel
can be stored on board.

The cruise industry is turning
to LNG as a new, greener

fuel source to power its ships.

So with Europa, we started
talking LNG over 10 years ago.

When we did that,
everyone thought we were crazy,

that we wouldn't be able to get
the fuel, but LNG is now

a mainstay for nearly all
the cruise lines and even in

a lot of the cargo vessels
that are being built today.

The company claims that
sailing World Europa in LNG

mode will almost eliminate
air pollutants like sulfur

and nitrogen oxides
from the ship and reduce

the vessel's greenhouse
gas emissions by 20%.

One of the biggest challenges
for Gaetano in the shipyard is

ensuring the prototype LNG
system is installed correctly.

Today, the team is gearing up
to install the largest part of

the system, the enormous tanks
that store the LNG fuel.

This is how they'll
attempt to do it.

Each of the vessel's two
voluminous LNG tanks measure

92 feet long
and weigh 343 tons.

To install them, the team will
use the yard's gantry crane to

lift the tanks over the ship,

carefully lower them

into the specially shaped
curved cradles.

The custom tanks have been
produced in China and must be

installed with the utmost care.

If a tank is damaged
during installation...

[loud thud]

...the team won't be able
to build the rest of the ship

until a new tank is delivered.

It could delay the
remaining construction work

by several months.

The tanks arrive from China
on board a cargo ship.

They are unloaded
at a nearby dock,

but must make the remaining
journey to the shipyard
by road.

The tanks are too large to be
loaded onto trucks, so the team

must use special multi-wheeled
heavy lift transporters.

♪♪

Under the cover of darkness,
the enormous tanks slowly begin

their journey to
the construction dock.

Workers carefully weave

the transporters through
Saint-Nazaire's narrow streets.

They squeeze the tanks around
the yard's tight bends

to reach the dockside close
to the giant gantry crane.

The team pushes through
the night to lift the tanks

on board the half-built vessel.

The following day, both tanks
are safely in position.

[Gaetano]
They take a lot of challenge
in order to fit the tanks

inside the hull.

It's taken a lot of time,
but finally,

all went well,

and the tank are fitted inside
the space

without any problem.

Now the shipyard can continue
to piece together more of

the liner's huge megablocks.

It takes around 17 months for
the shipyard to install all of

the vessel's 59 mammoth
megablocks,

including the uniquely
curved ship's bow,

the captain's bridge,

and the supports that will
hold the propellers.

As the bare skeleton of
the ship begins to take shape,

work on the interior
is just around the corner.

As the bare skeleton of this
massive cruise ship

takes shape, work on
the interior begins.

Didier Dupont oversees
the installation of thousands

of crew and passenger cabins on
all of the yard's new ships.

[speaking French]

Engineers must exploit every
inch of space onboard

a cruise ship
to ensure they can

accommodate as many passengers
as possible.

[speaking French]

Didier and the team face
a Herculean challenge.

It would take years
to build and furnish

each individual cabin
onboard a vessel one by one.

The team would never hit
their deadline,

and the ship would miss
its maiden voyage.

[man] Go!

To solve this problem,
the team has developed

an innovative solution at this
special factory near the yard.

When you come here,
you are in the cabin factory.

So, in this factory, we produce
all the prefabricated cabins

for world-class projects.

Thomaz Liernan oversees a team
of 250 workers who carefully

preassemble each one of
World Europa's 2,626 cabins

before they're installed
in the ship.

It's a very, very big cruise
ship with 4,000 cabins

to produce and everything
on time, so to do that, we have

to produce here in the factory

about one cabin
every 20 minutes.

The assembly of each cabin
begins with the wet unit

that houses the shower,
sink, and toilet.

[power tool whirring]

Workers bolt the cabins
together piece by piece,

just like flat-packed
furniture,

on this special
production line.

At the end of this
production line, the wet unit

is completely finished.

You have just to connect
the water and electricity

and you can use it.

Workers fit the faucets,
mirror, and shower head to

the unit's walls,
then lift them into place.

[Thomaz]
Now, we will use this wet unit
to produce the cabins.

The cabins move along
the production line,

so separate teams can install
the desk, bed, and electronics.

It is very, very challenge
for us in the factory to have

the cabin and the wet unit
without any missing
element inside.

This is the real challenge
for us.

After an astonishing
20 minutes,

the cabin is complete.

Only the carpet
and some furniture are left

to install on board.

[Thomaz]
OK, so now this is the cabin,
completely finished.

So the cabin, it will be ready
to go on board.

As you see, everything
is protected.

When we will do the inspection
at the end, we will not

discover some scratches,
something damaged.

So, we try to
protect everything.

Keeping an eye on the quality
of Thomaz's cabins

is Deborah Byrne.

I will show you this cabin.

Deborah works with the factory
to ensure that the team in

the shipyard receives
the cabins to install without

any defects or missing parts.

It's fabulous.

This is a new prototype,
so it's completely new for --

for all of us in this project.

We obviously have to keep on
our toes because

being a prototype,
sometimes there's a possibility

that what we see on paper,
once it's actually been built,

it could be some of that
doesn't quite work.

So, it's very important that

we pick up on any of
these points.

So, you see now the vanity is
new like that.

Oh, and I can see
the alignment now is

much better.
-[Thomaz] The alignment here
is good.

No gap.

[Deborah]
Obviously, this, now
the sharpness is gone,

and we've managed to do that
part much better.
-[Thomaz] Yeah.

-[Deborah] And the hairdryer?
-[Thomaz] The hairdryer, yes.

Dryer, you can remove.

[indistinct] is protected.

-And the hairdryer
is working already!
-Ah, so it's -- perfect!

-Perfect, and this is
the bracket for the TV?
-Yeah, bracket for the TV.

This cabin is signed off
and ready for installation.

Everything seems to be going
well, but we are at that

critical stage where we have
to be sure we're always

on our toes.

We keep the shipyard on
their toes as well, because any

slight delay will have
a knock-on effect

for all the other cabins.

The final task?

Shrink wrap the cabin to
protect it during its short

journey to the shipyard.

[Thomaz] Every cruise ship
is different.

At each time, it's a new story.

Sometimes new problems,
new difficulties,

but always a new challenge,
and always you have the target

to deliver the ship on time
with the best quality we can.

On the west coast of France,

a team of 3,000 shipbuilders
is racing to build

a nearly 1,100-foot-long,
ocean-going Goliath.

More than 20 months after
construction work began,

the bare frame of the ship
is complete.

Its exterior has been painted,

and the engines have
been installed.

Before the team can
load the cabins,

complete the swimming pools,

lounges,
and shopping promenade,

they need to move the vessel to
a different dock to allow for

easier access
to install and test

the ship's vital equipment.

To do this, they must first
attach the ship's two huge

propellers beneath the stern.

[Gaetano]
World Europa have two propeller
for propulsion.

The design was done

in terms to optimize all
vibration and comfort on board.

The challenge
for the ship's engineers

was to design propellers that
provide the best performance

without compromising
passenger comfort.

In 1907, during the sea trials

of the transatlantic liner
the Lusitania,

the world's biggest ship
at that time,

strong vibrations were detected
throughout the vessel.

The vibrations were so severe
that parts of the ship

were uninhabitable.

Investigations revealed
the vibrations came from

the ship's propellers.

It was caused by a phenomenon
known as cavitation.

The way to avoid
the cavitation is mainly

the design of the blade that
are done in such a way to avoid

this particular phenomenon
on the propeller.

Cavitation can occur when
a propeller rotates and creates

an area of low pressure
on the back of the blades,

causing tiny bubbles of vapor
to form.

When these bubbles collapse,
they send shock waves through

the water and onto
the ship's hull,

creating uncomfortable
vibrations on board.

To keep the ship from
vibrating, engineers must

design its propellers to
eliminate cavitation.

They slow the speed at which
the propellers rotate.

This reduces the area
of low pressure,

but also slows down the ship.

To compensate,
they design the propellers

with five blades.

They increase their size,
shape, and distance

from the hull.

These large,
slower-rotating propellers

should ensure the ship glides
smoothly through the water

without any
unpleasant vibrations.

The propellers will slot onto
two shaft lines that run

through the hull to
the engine rooms.

[Gaetano]
Here we have a big shaft line
of more than 60 meters

connecting the propeller
to the electric motors.

Engineers use a hydraulic ram

to position the shafts
inside the hull.

The ram grips the shaft
and slowly inches it into

the ship, sliding it towards
the engine room,

where it's connected to
the drive motors.

Now the team can
attach the propellers.

Each propeller is crafted from
a specially cast and milled

nickel aluminum alloy.

They use chains to carefully
lift each 26-ton propeller onto

the end of the shafts.

It takes great care
and precision to slot them into

place behind
the ship's giant rudders.

With the propellers attached,

the hull of World Europa
is finally complete.

The shipyard can now move
the $1.3 billion prototype

out of the construction dock
for the first time.

[indistinct chatter]

Workers fill the dock with
seawater to float the vessel.

And call in six tugs to
maneuver the mammoth ship,

with its futuristic bow design,

to her new home,

where work on the interior
spaces can ramp up.

Workers spring into action
the following morning.

[power tool buzzing]

They race to install and
furnish the ship's nine shops,

13 restaurants, and 20 bars,

including a lavish lounge
at the rear of the vessel.

The team installs
the world's longest
onboard dry slide,

a colossal casino,

and they fire up
the open-air promenade's
futuristic lighting.

But dockside,
Didier Dupont's team

is racing against the clock

to install a shipment of cabins
just arriving from the factory.

Dockside, Didier Dupont's team
is racing against the clock

to unwrap and install
a shipment of cabins

arriving from the factory.

[Didier speaking French]

To keep on top of the constant
stream of cabins,

Didier and his team use
an innovative method to load

them on board.

The ship is built with
a series of large holes

in its side on each deck.

The holes provide easy access
to install a deck's worth of

cabins on board.

The yard attaches a giant lift
to the outside of the vessel to

reach each hole.

So workers can load and lift
each cabin unit onto the ship.

Special rollers allow the team
to push the cabins on board,

squeezing them
through bulkheads

and around tight corners,

sliding them into position,
one after the other.

Once a deck has all its cabins
on board, workers fill the hole

to seal the level.

[speaking French]

The forklift operators must
ensure they place the cabins

onto the lift carefully so
they don't damage or dislodge

the furnishings inside.

[Didier speaking French]

The team prepares to haul
their fifteenth cabin

of the day through the ship.

The team wrestles
the 2.2-ton cabin
through the tight deck.

They must snake it through
a labyrinth of corridors

and equipment that cram
the ship's interior.

[speaking French]

[man]
Go, go, go, [indistinct].

[Didier speaking French]

A second team welds each cabin
to the deck floor

to lock them into place.

[speaking French]

It's hard but rewarding work
for the team.

[Didier speaking French]

As the clock counts down
towards delivery,

the pressure on the team
ramps up.

[power tool buzzing]

Over the next few weeks,

workers scramble
to finish the ship.

Engineers install
colossal chandeliers.

Chefs sharpen
their knife skills.

Waiters perfect
their silver service.

And the entertainers rehearse
their routines.

So, good morning.
How are you?

Everything fine?

In charge of
World Europa's guest experience

is Neven Zdunic.

Most beautiful part of my job
is to dealing with the guest

and to make them happy,
to realize their dreams.

Neven oversees every aspect of
the onboard experience,

from reception to
the entertainment
and dining service.

We go straight to the heart of
the hotel department,

reception, our staff that are
working to prepare all

the things what they need to
work with the guests.

Having onboard 6,700 guests,
and of course, we are the one

who has to give them
the direction where to go,

what to see, what to have,
because it's very important for

us to understand
well their needs.

One of Neven's customer
experiences is a unique

chocolate and gelato cafe.

[Neven]
As you can see, we are having
here a huge space where we are

gonna sell our homemade
chocolates and, of course,

together with that,
homemade ice cream.

-[Neven] Ah, Jean,
how is it going?
-Everything's good, thank you.

All good?
How is it going with
the ice cream?

You know, it's going good.

We almost finished with recipes
and digesting a little bit,

but I think they're
pretty good.

-You want to try?
-[Neven] Absolutely.

[Neven] Can we taste?
This is my favorite flavor.

[Jean-Phillipe]
So that's a raspberry flavor.

Our gelato are very
straight, simple --

it's milk, cream.

You know, we use
real chocolate.

We don't use, like,
cocoa powder or whatever.

-It's really, you know...
-[Neven] The real one.

[Jean-Phillipe] The real one.

If you're not in a good mood,
just taste one gelato

from Jean-Phillipe,
and then everything

will change in a better way.

Behind the scenes,
Jean-Phillipe's staff is racing

to finish elaborate sculptures
carved from solid chocolate

that will be featured
throughout his café.

It's a sprint to the finish
line for Neven's team to ensure

the ship is ready for
its maiden voyage.

[Neven] Right now,
concerning the construction,

the ship is almost ready.

Still, they are finishing
all the details.

Our staff, they clean,
they arrange the things,

they set up all the final items

which they need to put in
the right place.

Finally, after 36 months
of construction,

World Europa's delivery date
arrives.

The brand-new
$1.3 billion prototype,

with its ultra-modern
bow design

and open-air promenade,
is complete.

To celebrate this
momentous achievement,

the shipyard welcomes company
executives and the ship's crew

for a traditional
delivery ceremony.

[announcer]
And now, a big round
of applause, first of all,

for this work of art.

Ladies and gentlemen,
MSC World Europa!

[majestic music plays]

In a time-honored tradition,

the ship is blessed
ahead of setting sail.

[speaking French]

[woman speaking French]

Go!

Si!

Mamma mia!

The colossal cruise ship is
now ready to set sail to embark

passengers on her first
full cruise.

From one side, we are sad
for the leaving of the ship,

but on the other side,
we are really proud of

the product we built together.

♪♪

One of the vessel's first
ports of call is Dubai.

Here, the new ship
and its crew will undertake

the ultimate test.

Will everything be ready to
impress passengers

with high expectations?

On the west coast of France,
a team must now load

a week's worth
of food and drink

and ensure every cabin is
supplied with fresh linens

for the thousands of guests
due to board.

In the loading bay,

the team races to stock
the giant ship with

its crucial provisions.

Today, we are gonna loading
all the local supplier.

We're going to receive
22,000 kilo of meat,

3,000 kilo cheese,

10,000 liter milk,

45,000 fresh eggs,

and almost 18,000 kilo
vegetable fresh.

Every week, we receive at least
five or six containers

from Italy.

Liberato and his team must
ensure around 385 tons of food

make it on board ahead of each
week-long cruise.

As we can see,
we receive a lot of pallets

that we load directly from
the truck to the ship.

We're going to the storeroom,
to the cellar fridge.

In the same time, we will
check the quantity.

If we receive
the quantity we requested.

Before the fruit
and vegetables can be sent to

the onboard kitchens,
a sample must be checked for

quality and freshness.

The watermelon

look like good.

We have to test if can be also
sweet for give to our guest.

The quality of watermelon
is very good.

-Sweet.
-It's very sweet.

The grapes, the quality, it's...

-Small -- very small.
-Very small.

It's under
our standard quality.

But the taste is looking good.

It's so sweet.

We are going to make a quality
discrepancy for this item

because the size can be more

bigger than this for
the next time.

But the taste is very nice.
It's very sweet.

As the mountain of fresh
ingredients pile up...

Hello, welcome on board.
Hello.

...at the check-in terminal,
the pressure mounts for

the team as thousands of guests
start to arrive,

eager to board and explore
the new ship.

-[Anna] Passports, please.
-[passenger] Yeah.

-[Anna] And documents.
-[passenger] Yeah.

After three years of
construction and more than

7 million hours of hard work,

this prototype for a brand-new
class of cruise ship

is finally ready
for its first full cruise.

[Neven]
Today the ship is ready.

Everything is ready
for the guests.

Everything is running in
a perfect way.

And really, today we can say
that this dream became true.

More than 4,000 guests can now
explore the ship's 22 decks...

[passenger] Whoo!

...seven swimming pools,

and the chocolate cafe,
complete with sculptures.

The following morning,
the ship sets sail on

its maiden voyage around
the Middle East.

[Trevor]
My overall impressions of
Europa, now that she's sailing

and we've finished it,
is really pride that we've done

something that is so amazing,
big, fuel efficient,

latest technologies,
the best guest experience

that we can do.

It's thanks to the dedication
and hard work of thousands

of designers,
engineers, and onboard crew

that this colossal
$1.3 billion cruise ship

is ready to sail
the open oceans.

[ship horn blasts]