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Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated: 1 00:00:01,567 --> 00:00:03,000 [narrator] In the UK, 2 00:00:03,167 --> 00:00:05,100 engineers are taking on a seemingly 3 00:00:05,267 --> 00:00:07,300 impossible challenge. 4 00:00:07,467 --> 00:00:09,367 It'll be a massive feat of engineering. 5 00:00:11,100 --> 00:00:13,767 They're constructing a billion-dollar stadium 6 00:00:13,934 --> 00:00:15,367 on water. 7 00:00:15,534 --> 00:00:18,167 It's probably not the best place to build anything, 8 00:00:18,334 --> 00:00:19,467 let alone a stadium. 9 00:00:20,767 --> 00:00:23,868 This flat-pack design will rise in record time. 10 00:00:25,100 --> 00:00:28,667 Built from pieces made all over the country 11 00:00:28,834 --> 00:00:31,167 to hit a deadline set in stone. 12 00:00:31,334 --> 00:00:33,267 [Colin] We're playing Premier League football. 13 00:00:33,434 --> 00:00:36,267 We can't afford to miss it. We have to hit that date. 14 00:00:36,434 --> 00:00:39,100 The team needs to build in a bomb-strewn site... 15 00:00:39,267 --> 00:00:41,300 [rumbling] 16 00:00:41,467 --> 00:00:43,267 Drilling a pile through something like that would be 17 00:00:43,434 --> 00:00:44,567 game over, really. 18 00:00:44,734 --> 00:00:47,467 ...dodge fragile historic structures 19 00:00:47,634 --> 00:00:50,000 and battle wild waterfront winds. 20 00:00:50,167 --> 00:00:52,300 -[radio beeps] -[worker] Keep going, keep going, keep going. 21 00:00:52,467 --> 00:00:53,467 You're so close. 22 00:00:53,634 --> 00:00:54,667 [Alex] The last thing we want is 23 00:00:54,834 --> 00:00:56,167 falling bolts or falling plates. 24 00:00:57,601 --> 00:00:59,167 This incredible stadium 25 00:01:00,267 --> 00:01:04,400 ranks in a league of ambitious new engineering wonders 26 00:01:04,567 --> 00:01:08,868 that are bigger, faster, taller, and more advanced 27 00:01:09,033 --> 00:01:12,567 than anything ever constructed before. 28 00:01:12,734 --> 00:01:16,901 This is the inside story of the extraordinary challenge 29 00:01:17,067 --> 00:01:18,567 of building these giants. 30 00:01:29,167 --> 00:01:30,300 Liverpool, England. 31 00:01:32,200 --> 00:01:35,567 This city is famous worldwide for two things... 32 00:01:35,734 --> 00:01:37,667 [screaming] 33 00:01:37,834 --> 00:01:39,667 ...it's the hometown of The Beatles. 34 00:01:41,100 --> 00:01:45,100 And the city's half a million inhabitants are football crazy. 35 00:01:46,667 --> 00:01:48,868 Everton is the city's oldest football club. 36 00:01:50,868 --> 00:01:54,167 The team's stadium, Goodison Park, is a short walk 37 00:01:54,334 --> 00:01:56,400 from Liverpool's famous River Mersey. 38 00:01:58,701 --> 00:02:00,868 In 1892, Goodison became 39 00:02:01,033 --> 00:02:04,000 the first custom-built football stadium in the country. 40 00:02:06,067 --> 00:02:08,601 The thousands of workers from the bustling docks were 41 00:02:08,767 --> 00:02:10,968 the first supporters to pack the stands here. 42 00:02:12,767 --> 00:02:16,367 And establish a loyal fan base that's remained strong 43 00:02:16,534 --> 00:02:19,067 for over 130 years. 44 00:02:21,501 --> 00:02:23,567 Alix Waldron works for the club, 45 00:02:23,734 --> 00:02:26,934 and she comes from a family of Everton fans. 46 00:02:29,400 --> 00:02:33,100 The Park End, row FF, is the seats where I've been 47 00:02:33,267 --> 00:02:34,868 coming for years and years with my family. 48 00:02:35,033 --> 00:02:38,000 I essentially grew up here, coming sort of week in, 49 00:02:38,167 --> 00:02:39,868 week out with my dad and my uncles, 50 00:02:40,033 --> 00:02:42,000 my brother when he was born, and, you know, 51 00:02:42,167 --> 00:02:44,567 it holds so many special memories 52 00:02:44,734 --> 00:02:48,000 and, you know, that family unit that it feels like here. 53 00:02:49,167 --> 00:02:52,367 Goodison Park is precious to the 39,000 fans 54 00:02:52,534 --> 00:02:53,767 that come to every game. 55 00:02:55,067 --> 00:02:57,868 But the old ground is worn and run-down. 56 00:02:59,267 --> 00:03:03,567 There are another 34,000 people on a waiting list for tickets. 57 00:03:05,267 --> 00:03:07,667 Everton Football Club's solution is to build 58 00:03:07,834 --> 00:03:09,901 an ambitious brand-new stadium 59 00:03:10,067 --> 00:03:13,334 that boosts capacity by a third. 60 00:03:15,767 --> 00:03:18,167 The club has turned to world-renowned architect 61 00:03:18,334 --> 00:03:20,067 and stadium expert 62 00:03:20,234 --> 00:03:21,334 Dan Meis. 63 00:03:22,367 --> 00:03:24,968 He's designed ground-breaking sports arenas 64 00:03:25,133 --> 00:03:27,267 from America to Japan. 65 00:03:27,434 --> 00:03:28,868 When I first met with the club, 66 00:03:29,033 --> 00:03:31,200 the brief actually was very clear. 67 00:03:31,367 --> 00:03:33,267 Build a modern football stadium, 68 00:03:33,434 --> 00:03:35,300 but keep that intensity of Goodison. 69 00:03:36,400 --> 00:03:38,868 This is Dan's revolutionary design. 70 00:03:42,267 --> 00:03:44,100 This spectacular venue will 71 00:03:44,267 --> 00:03:47,000 seat more than 52,000 roaring fans 72 00:03:48,467 --> 00:03:52,934 in the UK's steepest terraces to create a wall of sound. 73 00:03:55,367 --> 00:04:00,868 Above the stands, 4,400 tons of structural steel support 74 00:04:01,033 --> 00:04:05,000 a 300,000 square-foot roof capping this sporting cauldron. 75 00:04:07,467 --> 00:04:08,567 Around the outside, 76 00:04:09,801 --> 00:04:11,300 sweeping aluminum cladding 77 00:04:12,467 --> 00:04:14,968 sits above an imposing brick facade 78 00:04:16,467 --> 00:04:18,667 that blends traditional with modern 79 00:04:18,834 --> 00:04:21,100 to reflect its historic Liverpool home. 80 00:04:25,200 --> 00:04:27,467 Finding a site for a new stadium in Liverpool 81 00:04:27,634 --> 00:04:28,767 is a big challenge. 82 00:04:30,367 --> 00:04:31,467 The city is crowded. 83 00:04:32,567 --> 00:04:35,601 There are few areas ripe for redevelopment close 84 00:04:35,767 --> 00:04:38,367 to Everton's spiritual home by the Liverpool docks. 85 00:04:40,767 --> 00:04:42,367 Historically, a lot of the, you know, 86 00:04:42,534 --> 00:04:44,701 the people who work down on the dockyards, 87 00:04:44,868 --> 00:04:46,501 they tend -- you know, they'd be football fans, 88 00:04:46,667 --> 00:04:48,467 they'd be going to Everton matches, 89 00:04:48,634 --> 00:04:51,667 they'd be leaving work here and walking up to Goodison Park 90 00:04:51,834 --> 00:04:53,167 to support the team. 91 00:04:55,567 --> 00:04:58,467 Club director Colin Chong has led the search 92 00:04:58,634 --> 00:05:01,000 for the club's new home for three years. 93 00:05:02,701 --> 00:05:06,467 He and the team have secured a 21-acre riverside plot 94 00:05:06,634 --> 00:05:09,067 called Bramley-Moore Dock. 95 00:05:09,234 --> 00:05:11,000 For a project as big as a stadium, 96 00:05:11,167 --> 00:05:13,567 there weren't really that many sites. 97 00:05:13,734 --> 00:05:16,467 We kept coming back to Bramley-Moore Dock. 98 00:05:16,634 --> 00:05:19,334 Unfortunately, the dock was predominantly water. 99 00:05:21,801 --> 00:05:24,501 Bramley-Moore Dock has been out of use for 40 years. 100 00:05:25,868 --> 00:05:27,400 It's roughly stadium-sized, 101 00:05:28,567 --> 00:05:31,367 but it's submerged under 26 feet of water. 102 00:05:32,701 --> 00:05:34,467 When I had a conversation with the old chairman, 103 00:05:34,634 --> 00:05:37,467 bless his soul, I did explain to him that where we chose to 104 00:05:37,634 --> 00:05:41,267 build the stadium was probably not the best place to build 105 00:05:41,434 --> 00:05:42,868 anything, let alone a stadium. 106 00:05:44,801 --> 00:05:47,767 The team faces a minefield of engineering challenges. 107 00:05:49,000 --> 00:05:52,801 The dock is enclosed by 170-year-old stone walls. 108 00:05:54,167 --> 00:05:57,200 A thick bed of soft silt sits below the water. 109 00:05:59,100 --> 00:06:02,367 The perimeter is dotted with fragile original dock features 110 00:06:03,667 --> 00:06:05,868 and an historic brick tower 111 00:06:06,033 --> 00:06:08,100 that are all protected by preservation orders. 112 00:06:09,968 --> 00:06:11,267 It's probably the worst site 113 00:06:11,434 --> 00:06:12,601 that we could have picked to build on 114 00:06:12,767 --> 00:06:15,400 but it'll be a real unique design. 115 00:06:15,567 --> 00:06:17,167 It's a massive feat of engineering 116 00:06:17,334 --> 00:06:19,200 to look at how do we do this? 117 00:06:20,868 --> 00:06:23,367 The first challenge the team faces is how to turn 118 00:06:23,534 --> 00:06:24,601 this water-filled site 119 00:06:26,300 --> 00:06:27,601 into a solid foundation. 120 00:06:28,767 --> 00:06:30,300 This is how they'll solve it. 121 00:06:31,868 --> 00:06:35,167 First, a boat combs the dock to remove debris. 122 00:06:36,167 --> 00:06:38,367 Next, the team fills the dock 123 00:06:38,534 --> 00:06:41,267 with nearly 16 million cubic feet of sand. 124 00:06:42,567 --> 00:06:45,767 Compactors pound the sand 60 times per minute 125 00:06:45,934 --> 00:06:47,734 with 10-ton hammers. 126 00:06:50,167 --> 00:06:53,467 Then, piling rigs use augers with hollow shafts 127 00:06:54,667 --> 00:06:58,334 to bore holes 52 feet down to bedrock. 128 00:07:00,868 --> 00:07:04,968 The rig operators inject concrete as the augers retract 129 00:07:05,133 --> 00:07:07,000 to prevent the bore holes from collapsing. 130 00:07:11,167 --> 00:07:14,300 Finally, workers push steel reinforcement cages 131 00:07:14,467 --> 00:07:16,667 into the wet concrete before it sets 132 00:07:17,868 --> 00:07:20,167 to create a forest of foundation piles 133 00:07:20,334 --> 00:07:21,367 for the team to build on. 134 00:07:29,200 --> 00:07:31,567 August, 2021. 135 00:07:31,734 --> 00:07:34,667 The stadium team begins raking the bottom of the dock 136 00:07:34,834 --> 00:07:37,000 to clear away any unwanted debris 137 00:07:39,067 --> 00:07:41,667 and makes a very unwelcome discovery. 138 00:07:42,868 --> 00:07:45,567 [Alix] We have found a couple of ordnance devices. 139 00:07:45,734 --> 00:07:46,801 A bomb. Yeah. 140 00:07:48,400 --> 00:07:51,801 Divers identify a total of 12 unexploded 141 00:07:51,968 --> 00:07:53,234 anti-aircraft rounds. 142 00:07:55,267 --> 00:07:58,167 The German Air Force dropped thousands of tons of bombs 143 00:07:58,334 --> 00:07:59,767 on Liverpool in World War II. 144 00:08:01,767 --> 00:08:04,167 Some of the bombs and anti-aircraft shells 145 00:08:04,334 --> 00:08:05,367 failed to detonate, 146 00:08:06,901 --> 00:08:08,667 and they are trapped in the dock's silt. 147 00:08:10,767 --> 00:08:13,367 It's a real danger that a machine on site 148 00:08:13,534 --> 00:08:16,534 could disturb one of these unexploded munitions. 149 00:08:18,968 --> 00:08:22,067 The team evacuates the dock area. 150 00:08:22,234 --> 00:08:24,000 Drilling a pile through something like that would be 151 00:08:24,167 --> 00:08:26,901 game over, really, so it has to happen to make sure that, 152 00:08:27,067 --> 00:08:28,100 you know, it's safe for people 153 00:08:28,267 --> 00:08:30,200 to carry on with the next phases. 154 00:08:41,767 --> 00:08:43,701 Engineers in Liverpool, England 155 00:08:43,868 --> 00:08:46,167 are building a brand-new super stadium 156 00:08:46,334 --> 00:08:47,901 for the Everton Football Club. 157 00:08:49,501 --> 00:08:53,200 An explosive ordnance disposal unit removes the larger devices 158 00:08:53,367 --> 00:08:55,167 to be dismantled off-site 159 00:08:57,601 --> 00:08:59,567 and explodes the smaller devices 160 00:09:02,100 --> 00:09:03,167 next to the dock. 161 00:09:05,601 --> 00:09:07,300 With the danger now handled, 162 00:09:07,467 --> 00:09:09,267 the engineers restart their work. 163 00:09:13,167 --> 00:09:15,167 They need to empty the dock of water. 164 00:09:16,667 --> 00:09:19,300 But simply draining it will allow the massive weight 165 00:09:19,467 --> 00:09:23,067 of the River Mersey to collapse the 170-year-old dock wall, 166 00:09:25,467 --> 00:09:28,167 turning the dock into part of the river. 167 00:09:30,601 --> 00:09:33,300 To solve this problem, the engineers devise 168 00:09:33,467 --> 00:09:35,133 an ingenious solution. 169 00:09:37,567 --> 00:09:39,467 They bring in a special dredger. 170 00:09:40,767 --> 00:09:43,267 It scoops up hundreds of tons of sand from 171 00:09:43,434 --> 00:09:44,567 the mouth of the River Mersey. 172 00:09:48,267 --> 00:09:51,501 The dredger mixes the sand with river water to make a slurry. 173 00:09:54,801 --> 00:09:57,067 It pumps this along a reinforced pipe 174 00:09:57,234 --> 00:09:59,501 directly into the dock. 175 00:10:01,968 --> 00:10:04,567 The sand in the slurry sinks to the bottom of the dock 176 00:10:04,734 --> 00:10:06,767 and displaces the water. 177 00:10:06,934 --> 00:10:10,100 Pumps then drain this water into the river. 178 00:10:10,267 --> 00:10:12,400 The dock itself is never empty at any stage. 179 00:10:12,567 --> 00:10:14,467 And then, eventually, the water will be 180 00:10:14,634 --> 00:10:16,801 completely removed and the sand 181 00:10:16,968 --> 00:10:21,367 becomes a solid mass of material. 182 00:10:21,534 --> 00:10:25,100 After eight weeks of pumping, a giant expanse of sand 183 00:10:25,267 --> 00:10:26,367 emerges from the water. 184 00:10:29,968 --> 00:10:33,934 Two weeks later, the dock is almost completely full. 185 00:10:36,400 --> 00:10:40,801 Giant compactors hammer down the 43,000 square feet of sand. 186 00:10:48,367 --> 00:10:49,968 This makes the dock solid enough 187 00:10:50,133 --> 00:10:51,367 to start foundation piling. 188 00:11:01,601 --> 00:11:03,467 Pile drivers begin drilling down 189 00:11:03,634 --> 00:11:05,868 to the compacted sand and into bedrock. 190 00:11:10,801 --> 00:11:13,868 The hollow drills fill the 24-inch-wide holes 191 00:11:14,033 --> 00:11:17,167 with concrete as they pull up and out of the ground. 192 00:11:21,901 --> 00:11:25,100 Crane teams then insert cages made from steel 193 00:11:25,267 --> 00:11:26,667 to reinforce the concrete. 194 00:11:27,801 --> 00:11:29,300 [worker] Hey, hey, hey, hey! 195 00:11:29,467 --> 00:11:32,167 Seven months and 2,700 piles later, 196 00:11:33,300 --> 00:11:36,701 the stadium team has a solid base to build on. 197 00:11:36,868 --> 00:11:38,767 [worker] Keep going, keep going, keep going. 198 00:11:38,934 --> 00:11:40,701 Now begins the task of constructing 199 00:11:40,868 --> 00:11:42,400 the stadium's concrete skeleton. 200 00:11:44,567 --> 00:11:45,701 [worker] Hold off that. 201 00:11:45,868 --> 00:11:47,167 There's another one in. 202 00:11:49,467 --> 00:11:53,100 It takes the team 10 months to turn a water-filled dock 203 00:11:53,267 --> 00:11:55,934 into a dry and stable foundation. 204 00:11:58,367 --> 00:12:01,267 The next challenge is to build the concrete walls, 205 00:12:01,434 --> 00:12:03,501 floor, and stairs of the stadium. 206 00:12:05,167 --> 00:12:07,667 Now that the crews are working above ground, 207 00:12:07,834 --> 00:12:09,534 they need to factor in the wind. 208 00:12:12,000 --> 00:12:13,767 It's one of the windiest places 209 00:12:13,934 --> 00:12:15,868 and one of the windiest cities in the UK. 210 00:12:16,033 --> 00:12:19,100 So the weather conditions that we're exposed to here 211 00:12:19,267 --> 00:12:20,567 call for a different way, 212 00:12:20,734 --> 00:12:22,701 different methodology of building. 213 00:12:22,868 --> 00:12:25,300 Add to that a deadline of three years 214 00:12:25,467 --> 00:12:27,067 to complete the project, 215 00:12:27,234 --> 00:12:30,868 the team needs a faster way to build with concrete. 216 00:12:31,033 --> 00:12:33,567 The solution is to build the stadium in parts 217 00:12:33,734 --> 00:12:37,234 in a workshop and ship these to the site. 218 00:12:39,667 --> 00:12:43,100 [Colin] Whilst we're actually filling the dock in, carrying out some 219 00:12:43,267 --> 00:12:45,667 of the piled foundations and some of the existing 220 00:12:45,834 --> 00:12:49,167 hardscape, we're manufacturing product off-site. 221 00:12:49,334 --> 00:12:51,267 So as soon as those foundations are ready 222 00:12:51,434 --> 00:12:54,734 to receive a wall, the wall will be in. 223 00:12:57,167 --> 00:13:00,667 This huge factory, 100 miles away in Worksop, 224 00:13:01,801 --> 00:13:05,367 has the task of manufacturing the 30,000 tons of concrete 225 00:13:05,534 --> 00:13:08,334 components that form the Everton Stadium. 226 00:13:10,767 --> 00:13:14,467 400 workers operate giant rigs that produce building 227 00:13:14,634 --> 00:13:17,300 components in hours instead of days. 228 00:13:19,767 --> 00:13:22,167 The computer-controlled machines pour concrete 229 00:13:22,334 --> 00:13:23,267 into a flat mold. 230 00:13:25,100 --> 00:13:27,000 And once it's dry, turn it over 231 00:13:29,367 --> 00:13:32,067 and place it into another mold. 232 00:13:34,501 --> 00:13:37,968 This produces pristine-looking sections of wall that require 233 00:13:38,133 --> 00:13:40,000 no extra finishing when they get to the site. 234 00:13:45,300 --> 00:13:48,901 Everything made inside the factory must fit perfectly. 235 00:13:51,067 --> 00:13:53,100 When a component leaves the assembly line, 236 00:13:53,267 --> 00:13:55,767 there will be no chance for any adjustments. 237 00:13:57,501 --> 00:14:00,067 The team's solution is to give everyone access 238 00:14:00,234 --> 00:14:02,300 to a 3D computer model of the stadium. 239 00:14:07,000 --> 00:14:08,667 There are no paper plans. 240 00:14:09,667 --> 00:14:12,367 The stadium's model directly links with the automated 241 00:14:12,534 --> 00:14:14,501 assembly lines at sites like this one. 242 00:14:16,701 --> 00:14:18,868 Architect Jon-Scott Kohli 243 00:14:19,033 --> 00:14:21,167 runs a digital version of the build process. 244 00:14:23,467 --> 00:14:27,000 This is a master plan for all crews working on the project. 245 00:14:31,000 --> 00:14:33,400 Spending the time of thinking through all of the problems 246 00:14:33,567 --> 00:14:36,267 and, you know, building a sort of a 3D model a bit like this, 247 00:14:36,434 --> 00:14:38,767 where process of getting information to the right people 248 00:14:38,934 --> 00:14:41,000 at the right time so that you can go fast. 249 00:14:43,100 --> 00:14:45,567 At the build site, the workers take delivery of 250 00:14:45,734 --> 00:14:48,868 the first batch of concrete panels to make the core 251 00:14:49,033 --> 00:14:50,868 structures at each corner of the stadium. 252 00:14:54,767 --> 00:14:57,367 The panels arrive on the back of a low-loader. 253 00:14:58,868 --> 00:15:01,901 Workers use a mobile crane to lift each panel 254 00:15:02,067 --> 00:15:03,067 to the installation site. 255 00:15:04,167 --> 00:15:05,501 -[radio beeps] [worker] Hold her there. 256 00:15:05,667 --> 00:15:08,567 The crane operator carefully installs the panels. 257 00:15:08,734 --> 00:15:10,000 [worker speaks indistinctly] 258 00:15:10,901 --> 00:15:13,701 So that the steel attaches to the foundation's threads. 259 00:15:21,267 --> 00:15:25,067 Workers then fill the void inside each panel with concrete 260 00:15:25,234 --> 00:15:26,934 to lock it in place. 261 00:15:29,367 --> 00:15:32,567 The crew repeats this process at each corner of the stadium. 262 00:15:34,567 --> 00:15:37,868 [Alix] The prefab element does allow us to speed up the program. 263 00:15:38,033 --> 00:15:40,467 You know, it does happen quite rapidly before you rise. 264 00:15:40,634 --> 00:15:42,100 You know, you think, "Oh, we're starting that next week," 265 00:15:42,267 --> 00:15:44,367 and all of a sudden, you know, you're 30% there, 266 00:15:44,534 --> 00:15:46,467 and you think, "That's just flown by." 267 00:15:48,100 --> 00:15:51,167 The stadium's staircases are some of the most challenging 268 00:15:51,334 --> 00:15:52,400 components to install. 269 00:15:56,467 --> 00:15:59,100 Stairs are a critical part of the stadium structure. 270 00:16:00,501 --> 00:16:04,067 They must be large enough and tough enough to support 271 00:16:04,234 --> 00:16:06,267 the tens of thousands of fans 272 00:16:06,434 --> 00:16:08,501 as they make their way to and from their seats. 273 00:16:10,267 --> 00:16:13,868 This is a major test of the pre-built method. 274 00:16:14,033 --> 00:16:17,801 The stairs span multiple levels and have anchor points at both 275 00:16:17,968 --> 00:16:19,868 ends that connect perfectly. 276 00:16:21,901 --> 00:16:24,367 Every element that's going to go to the precast concrete 277 00:16:24,534 --> 00:16:27,000 factory needs to be in the model and needs to be 278 00:16:27,167 --> 00:16:28,100 the right size, the right shape, 279 00:16:28,267 --> 00:16:29,868 it's got to have the right holes in it. 280 00:16:30,033 --> 00:16:31,968 The opening that's formed in the factory has to be 281 00:16:32,133 --> 00:16:35,167 the correct size at the first time. 282 00:16:35,334 --> 00:16:36,868 -[radio beeps] -[worker] Winch up slowly again. 283 00:16:37,033 --> 00:16:40,667 The crane crew needs to raise the 26-foot-long staircase 284 00:16:40,834 --> 00:16:42,000 at just the right angle. 285 00:16:43,267 --> 00:16:44,501 Because when the crane operator 286 00:16:44,667 --> 00:16:46,167 lowers it into the open building, 287 00:16:48,067 --> 00:16:50,400 it must slot between the existing walls 288 00:16:50,567 --> 00:16:53,300 and floor edges without taking any hits. 289 00:16:53,467 --> 00:16:55,200 [worker] Hold off that. 290 00:16:57,667 --> 00:16:59,567 One foot to go. Keep coming down. 291 00:17:00,667 --> 00:17:03,267 The staircase holes must land precisely 292 00:17:03,434 --> 00:17:05,367 on the reinforcement steel. 293 00:17:05,534 --> 00:17:07,167 Hold off that. 294 00:17:07,334 --> 00:17:08,901 There's no room for error. 295 00:17:17,801 --> 00:17:21,267 Engineers in Liverpool are building a brand new stadium 296 00:17:21,434 --> 00:17:23,000 for the Everton Football Club. 297 00:17:24,467 --> 00:17:26,000 -[radio beeps] -[worker] Winch up slowly again. 298 00:17:26,167 --> 00:17:29,868 The crane crew needs to raise the 26-foot-long staircase 299 00:17:30,033 --> 00:17:32,167 at just the right angle. 300 00:17:32,334 --> 00:17:34,767 The staircase holes must land precisely 301 00:17:34,934 --> 00:17:36,067 on the reinforcement steel. 302 00:17:37,100 --> 00:17:38,100 Hold it there. 303 00:17:42,267 --> 00:17:43,801 It fits. 304 00:17:43,968 --> 00:17:45,767 [worker] So, yeah, we're good then. 305 00:17:45,934 --> 00:17:49,100 The crew releases the crane ties and the structure takes 306 00:17:49,267 --> 00:17:50,868 another big step forward. 307 00:17:54,467 --> 00:17:57,167 Just a few months after finishing the foundations, 308 00:17:57,334 --> 00:17:59,501 the multi-level structure is rising up 309 00:17:59,667 --> 00:18:01,100 at each corner of the stadium. 310 00:18:05,367 --> 00:18:08,300 The concrete stair blocks mark out the scale of the site. 311 00:18:10,067 --> 00:18:13,267 Now the engineers must build the four giant stands 312 00:18:13,434 --> 00:18:14,567 in between them. 313 00:18:17,000 --> 00:18:18,767 The concrete facility in Worksop 314 00:18:18,934 --> 00:18:20,467 is producing a steady stream 315 00:18:20,634 --> 00:18:22,100 of prefabricated panels. 316 00:18:23,667 --> 00:18:26,167 But it's now that the team must begin to install 317 00:18:26,334 --> 00:18:28,000 the stadium's steel components. 318 00:18:30,267 --> 00:18:33,701 Typically, we see stadium designs either being built 319 00:18:33,868 --> 00:18:35,868 where the main superstructure, you know, 320 00:18:36,033 --> 00:18:38,667 the structure above ground, is either done in steel 321 00:18:38,834 --> 00:18:39,868 or it's done in concrete. 322 00:18:40,033 --> 00:18:40,968 But here we're doing both. 323 00:18:42,901 --> 00:18:45,200 Trucks deliver large steel beams, 324 00:18:47,267 --> 00:18:50,667 and crane teams lift them to the north and south sides 325 00:18:50,834 --> 00:18:52,567 of the stadium. 326 00:18:52,734 --> 00:18:55,701 [Jon-Scott] The benefit of using both systems is that we're then able 327 00:18:55,868 --> 00:18:58,567 to use even more factories, which allows more 328 00:18:58,734 --> 00:19:00,901 of the stadium to be built kind of at once 329 00:19:01,067 --> 00:19:04,000 and then brought to site and directed quickly. 330 00:19:06,167 --> 00:19:08,267 The steel crews swing into action. 331 00:19:10,267 --> 00:19:13,367 They bolt together the huge steel elements to assemble 332 00:19:13,534 --> 00:19:16,467 the framework that will support the stadium's four stands. 333 00:19:20,801 --> 00:19:24,467 Crews on the east and west sides continue to slot together 334 00:19:24,634 --> 00:19:27,767 prefabricated concrete to join up the four corners. 335 00:19:29,367 --> 00:19:31,467 All these kind of concrete and steel elements are coming 336 00:19:31,634 --> 00:19:33,767 to site and being kind of bolted together 337 00:19:33,934 --> 00:19:35,567 or slotted into place. 338 00:19:35,734 --> 00:19:37,100 It's good for the soul, I have to say, 339 00:19:37,267 --> 00:19:39,167 to be able to kind of see a building like this 340 00:19:39,334 --> 00:19:42,067 growing out of the dock so quickly. 341 00:19:44,267 --> 00:19:47,100 14 months into the build, construction crews 342 00:19:47,267 --> 00:19:49,200 have completed the structure's footprint. 343 00:19:51,667 --> 00:19:56,434 And this 52,000-seater stadium is on the rise. 344 00:19:58,868 --> 00:20:02,367 Steel columns support the roof on three sides of the original 345 00:20:02,534 --> 00:20:05,367 stadium and obstruct the view of the game 346 00:20:05,534 --> 00:20:07,267 for more than half of the spectators. 347 00:20:08,801 --> 00:20:12,567 Every seat in the new stadium at Bramley-Moore Dock must have 348 00:20:12,734 --> 00:20:14,467 an unobstructed view of the pitch. 349 00:20:16,501 --> 00:20:19,467 The roof covers 300,000 square feet. 350 00:20:21,701 --> 00:20:24,000 It needs a huge framework to hold it up. 351 00:20:26,000 --> 00:20:28,367 Across the North and the South stand, we've got these really, 352 00:20:28,534 --> 00:20:32,067 really big trusses that span from one side to the other. 353 00:20:32,234 --> 00:20:35,100 The longest of these spans is about 170 meters. 354 00:20:35,267 --> 00:20:37,167 The tallest of them is about 11 meters high. 355 00:20:37,334 --> 00:20:40,467 I mean, that's -- that's taller than my house, right? 356 00:20:40,634 --> 00:20:42,100 So if you can imagine a residential street, 357 00:20:42,267 --> 00:20:44,601 you know, that is what the scale of those trusses are. 358 00:20:46,100 --> 00:20:49,567 Each of the five spans weighs 220 tons. 359 00:20:50,868 --> 00:20:54,033 They're too large and heavy to lift in one pass. 360 00:20:56,467 --> 00:20:59,667 So the team must use a special technique to lift them 361 00:20:59,834 --> 00:21:01,100 separately in stages. 362 00:21:06,100 --> 00:21:10,133 An off-site factory delivers dozens of beams and columns. 363 00:21:12,567 --> 00:21:15,801 And steelworkers bolt them into giant frames 364 00:21:15,968 --> 00:21:17,901 one third of the trusses' length. 365 00:21:20,367 --> 00:21:24,067 A crawler crane lifts the first 230-foot-long section 366 00:21:25,767 --> 00:21:28,300 and lowers it onto a temporary support tower. 367 00:21:29,767 --> 00:21:33,000 Then, workers lift and bolt the next section 368 00:21:33,167 --> 00:21:34,267 onto the first. 369 00:21:35,567 --> 00:21:37,834 When the entire framework is up and connected, 370 00:21:40,267 --> 00:21:42,267 the crew lowers the support towers, 371 00:21:43,767 --> 00:21:46,400 and the trusses finally hold their own weight, 372 00:21:48,267 --> 00:21:49,868 settling by 17 inches 373 00:21:51,801 --> 00:21:54,367 to finish in precisely the right shape. 374 00:21:59,868 --> 00:22:03,000 This huge steel fabrication plant, 31 miles away 375 00:22:03,167 --> 00:22:04,968 from the stadium, builds the trusses. 376 00:22:08,567 --> 00:22:12,400 The workers here cut, grind, and weld the huge steel 377 00:22:12,567 --> 00:22:14,067 sheets, beams, and tubes 378 00:22:16,100 --> 00:22:18,467 into millimeter-precise structural elements. 379 00:22:24,400 --> 00:22:28,000 It falls to design engineer Alex Heaton to supervise 380 00:22:28,167 --> 00:22:30,801 the installation of these massive steel structures. 381 00:22:32,400 --> 00:22:35,868 The huge size of the roof truss means that his team must 382 00:22:36,033 --> 00:22:39,100 send it to the site one piece at a time. 383 00:22:39,267 --> 00:22:42,267 Alex will spend the next eight months at the stadium site 384 00:22:42,434 --> 00:22:44,767 to oversee and coordinate every aspect 385 00:22:44,934 --> 00:22:46,267 of this monster roof build. 386 00:22:47,467 --> 00:22:49,667 When the trusses start arriving, I'll be putting 387 00:22:49,834 --> 00:22:52,667 the pieces for the trusses on the pitch right near 388 00:22:52,834 --> 00:22:54,267 the container temporary works that we're using 389 00:22:54,434 --> 00:22:55,567 to assemble it. 390 00:22:59,300 --> 00:23:01,367 Low loaders deliver the truss sections. 391 00:23:03,000 --> 00:23:04,267 A crane lifts them to 392 00:23:04,434 --> 00:23:06,567 the center of the stadium, where the pitch will be, 393 00:23:08,100 --> 00:23:10,701 and the steel team assembles them. 394 00:23:13,167 --> 00:23:16,267 The sections are so enormous that the steel team needs 395 00:23:16,434 --> 00:23:18,901 to assemble them, propped up against a row 396 00:23:19,067 --> 00:23:23,267 of giant shipping containers, stacked two units high. 397 00:23:23,434 --> 00:23:25,467 [Jon-Scott] When you suddenly start seeing those being erected against 398 00:23:25,634 --> 00:23:29,100 stacks of shipping containers as if they were Duplo blocks, 399 00:23:29,267 --> 00:23:31,467 then you really begin to understand 400 00:23:31,634 --> 00:23:32,801 the, kind of, the scale of what 401 00:23:32,801 --> 00:23:34,767 we're actually -- what we're actually building here. 402 00:23:35,868 --> 00:23:37,701 Alex checks the angle of deflection 403 00:23:37,868 --> 00:23:39,200 across every truss section. 404 00:23:41,667 --> 00:23:43,167 The piece is 30 meters long. 405 00:23:43,334 --> 00:23:45,901 If this is only, you know, an 0.1 degree out, 406 00:23:46,067 --> 00:23:49,100 that's a long distance over a 30-meter distance, 407 00:23:49,267 --> 00:23:51,167 so it won't join up at the end. 408 00:23:51,334 --> 00:23:54,000 Alex also keeps one eye on the weather forecast. 409 00:23:55,000 --> 00:23:58,701 A wind speed above 23 feet per second could make the truss 410 00:23:58,868 --> 00:24:01,400 swing dangerously during the lift. 411 00:24:01,567 --> 00:24:04,601 We always ensure we pick calm days when we're doing these 412 00:24:04,767 --> 00:24:07,467 lifts, especially the big 70-meter-long ones, 413 00:24:07,634 --> 00:24:09,367 because once you pick something up, you never really want to 414 00:24:09,534 --> 00:24:10,701 have to put it back down again. 415 00:24:13,167 --> 00:24:15,767 When the first calm day arrives, 416 00:24:15,934 --> 00:24:17,567 the crawler crane makes the lift, 417 00:24:18,767 --> 00:24:22,400 and workers with guide ropes carefully walk the first huge 418 00:24:22,567 --> 00:24:23,767 truss section into position. 419 00:24:27,801 --> 00:24:31,400 Steelworkers bolt one end in place, and they fix the other 420 00:24:31,567 --> 00:24:32,467 to a support tower. 421 00:24:34,801 --> 00:24:37,100 The first lift is a success. 422 00:24:40,767 --> 00:24:43,000 Over five months, the team 423 00:24:43,167 --> 00:24:46,267 lifts, guides, and installs the remaining 424 00:24:46,434 --> 00:24:50,300 14 truss sections to complete the roof's support structure. 425 00:24:51,667 --> 00:24:54,100 Alex and the steel team inch down the jacks 426 00:24:54,267 --> 00:24:56,467 on each tower and turn. 427 00:24:56,634 --> 00:25:00,467 The trusses support their own weight for the first time. 428 00:25:00,634 --> 00:25:02,801 And because the team overestimated the number of 429 00:25:02,968 --> 00:25:06,767 days canceled due to wind, Alex can sign off on the lift 430 00:25:06,934 --> 00:25:08,868 operation ahead of schedule. 431 00:25:10,100 --> 00:25:11,200 It was a really good feeling to know 432 00:25:11,367 --> 00:25:12,667 that it's all been finished. 433 00:25:12,834 --> 00:25:13,868 And we're on program, 434 00:25:14,033 --> 00:25:16,267 if not a good few weeks ahead of program. 435 00:25:16,434 --> 00:25:19,267 So God must be an Everton fan, yeah. 436 00:25:19,434 --> 00:25:23,000 The stadium's outline is visible for the first time. 437 00:25:23,167 --> 00:25:25,767 Now the team needs to turn this skeleton 438 00:25:25,934 --> 00:25:28,367 into a fully-fledged sports arena. 439 00:25:39,300 --> 00:25:42,501 In Liverpool, England, engineers are racing 440 00:25:42,667 --> 00:25:46,367 to raise a brand-new stadium for the Everton Football Club. 441 00:25:48,100 --> 00:25:51,367 Architect Dan Meis designs the new arena to blend with 442 00:25:51,534 --> 00:25:54,000 the industrial heritage of the surrounding structures, 443 00:25:56,100 --> 00:25:57,667 like the famous Titanic building 444 00:25:59,200 --> 00:26:00,567 and the tobacco warehouse. 445 00:26:01,801 --> 00:26:03,701 It was very clear to me that this building needed 446 00:26:03,868 --> 00:26:05,267 a sense of history. 447 00:26:05,434 --> 00:26:06,667 It needed the kind of gravity 448 00:26:06,834 --> 00:26:09,701 that a brick building would deliver. 449 00:26:12,167 --> 00:26:17,100 The design encases the stadium in a nearly 60-foot high facade 450 00:26:17,267 --> 00:26:20,067 made up of slender, stand-alone brick piers. 451 00:26:21,667 --> 00:26:24,267 This choice presents a challenge to the engineers 452 00:26:24,434 --> 00:26:25,534 building the stadium. 453 00:26:26,868 --> 00:26:29,400 It would take an army of bricklayers months 454 00:26:29,567 --> 00:26:33,067 to lay 243 courses of bricks in a simple wall 455 00:26:33,234 --> 00:26:34,467 around the stadium. 456 00:26:36,667 --> 00:26:39,767 Laying bricks in short stretches to create the narrow, 457 00:26:39,934 --> 00:26:41,667 perfectly straight piers by hand 458 00:26:42,801 --> 00:26:44,000 would be near impossible. 459 00:26:46,367 --> 00:26:48,501 The team needs a way to lay real bricks, 460 00:26:48,667 --> 00:26:50,968 but with machine-like accuracy and speed. 461 00:26:53,167 --> 00:26:55,267 Their off-site construction factory has 462 00:26:55,434 --> 00:26:57,434 a game-changing solution. 463 00:26:59,868 --> 00:27:03,467 Handmade bricks are cut into half a million thin slices 464 00:27:03,634 --> 00:27:04,801 called brick slips, 465 00:27:06,901 --> 00:27:10,000 each one with a special profile cut into its back. 466 00:27:11,467 --> 00:27:13,801 The factory team follows a preset plan 467 00:27:13,968 --> 00:27:15,067 to lay down each brick 468 00:27:16,267 --> 00:27:18,000 into large, flat molds. 469 00:27:20,100 --> 00:27:23,567 Computer-controlled machinery places a steel reinforcement 470 00:27:23,734 --> 00:27:24,634 cage on top 471 00:27:25,801 --> 00:27:27,667 and fills the mold with concrete 472 00:27:27,834 --> 00:27:29,534 to make one solid panel. 473 00:27:32,000 --> 00:27:35,601 Trucks deliver the panels exactly when needed, 474 00:27:35,767 --> 00:27:38,667 and crane crews bolt them into place 475 00:27:38,834 --> 00:27:41,767 to cover the stadium facade in a fraction of the time 476 00:27:41,934 --> 00:27:43,767 compared to traditional bricklaying. 477 00:27:50,501 --> 00:27:54,501 For 18 months in Worksop, the pre-build team dedicates 478 00:27:54,667 --> 00:27:57,200 one section of the cavernous facility to placing 479 00:27:57,367 --> 00:27:58,968 crate after crate of brick slips. 480 00:28:04,167 --> 00:28:07,267 The key profile on the back of the bricks bonds with 481 00:28:07,434 --> 00:28:11,367 the concrete that automated hoppers pour into each mold. 482 00:28:18,701 --> 00:28:22,000 The first brick panels begin arriving on site, 483 00:28:22,167 --> 00:28:24,767 millimeter-accurate and ready for installation. 484 00:28:26,601 --> 00:28:28,901 So to get that perfect by hand 485 00:28:29,067 --> 00:28:30,701 would have been near on impossible, I think. 486 00:28:30,868 --> 00:28:34,167 So to be able to do stuff like this in factory settings, 487 00:28:34,334 --> 00:28:37,601 it's far safer for people and there's a lot less wastage 488 00:28:37,767 --> 00:28:38,968 for us as well. 489 00:28:40,067 --> 00:28:42,667 The crane crews must handle the panels with care. 490 00:28:44,100 --> 00:28:47,167 The shallow brick slips are more fragile than concrete. 491 00:28:48,801 --> 00:28:51,400 One knock could cause enough damage to render 492 00:28:51,567 --> 00:28:54,267 the entire panel unusable. 493 00:28:54,434 --> 00:28:57,100 Making a replacement will cost time and money. 494 00:28:59,567 --> 00:29:01,467 The design team has a solution. 495 00:29:03,167 --> 00:29:06,868 Special threaded inserts allow the crane team to screw hook 496 00:29:07,033 --> 00:29:08,868 attachments straight into the concrete. 497 00:29:11,100 --> 00:29:14,868 This means no slings or hooks can bump the panel's bricks 498 00:29:15,033 --> 00:29:16,000 as the team lifts it. 499 00:29:22,367 --> 00:29:25,901 It takes the crane team just two-and-a-half hours to install 500 00:29:26,067 --> 00:29:28,300 the first panels after they arrive on site. 501 00:29:33,367 --> 00:29:36,100 Every panel the crew fixes to the outside of the structure 502 00:29:38,400 --> 00:29:41,000 makes the stadium look more like an enclosed building. 503 00:29:45,300 --> 00:29:48,567 On the inside, construction crews start to fit 504 00:29:48,734 --> 00:29:52,601 partition walls and cover over the gaps between the different 505 00:29:52,767 --> 00:29:54,767 parts of the stadium structure. 506 00:29:54,934 --> 00:29:58,467 This sort of paneling has got a small air gap underneath 507 00:29:58,634 --> 00:30:00,100 there between the different elements of the build, 508 00:30:00,267 --> 00:30:01,567 the steel and the concrete. 509 00:30:01,734 --> 00:30:04,467 And it just allows for the way they expand and contract 510 00:30:04,634 --> 00:30:05,934 with the different weather conditions. 511 00:30:07,067 --> 00:30:10,467 The stadium is a series of freestanding structures built 512 00:30:10,634 --> 00:30:12,100 from either concrete or steel. 513 00:30:14,000 --> 00:30:18,100 The flexible rubber strips like this cover gaps and allow 514 00:30:18,267 --> 00:30:20,801 the different sections to expand and contract. 515 00:30:25,000 --> 00:30:27,100 [Alix] There are multiple movement joints around the build, 516 00:30:27,267 --> 00:30:29,200 and fans will just walk straight past it and not 517 00:30:29,367 --> 00:30:30,868 realize the kind of engineering 518 00:30:31,033 --> 00:30:32,667 design that's gone into the finish there. 519 00:30:33,968 --> 00:30:37,000 On the outside, black expansion panels between 520 00:30:37,167 --> 00:30:40,534 the brick sections allow a similar degree of movement. 521 00:30:43,000 --> 00:30:46,400 After 10 months of work, the crane team installs 522 00:30:46,567 --> 00:30:50,868 the last of 745 panels to complete the brick facade. 523 00:30:53,167 --> 00:30:55,167 Architect Dan Meis visits to 524 00:30:55,334 --> 00:30:57,167 see how his vision is taking shape. 525 00:30:59,267 --> 00:31:01,868 It's easy for me to draw some lines and put some red color 526 00:31:02,033 --> 00:31:04,701 on it and say, "It's going to be a giant brick wall." 527 00:31:04,868 --> 00:31:07,267 Then trying to figure out exactly how that gets built 528 00:31:07,434 --> 00:31:09,400 and how it gets built in the sequence of construction, 529 00:31:09,567 --> 00:31:12,000 that's all a very complex thing. 530 00:31:12,167 --> 00:31:14,067 But seeing them in place, it's really incredible. 531 00:31:15,868 --> 00:31:19,000 The brick pier facade echoes the industrial heritage of 532 00:31:19,167 --> 00:31:21,100 Liverpool's docks perfectly. 533 00:31:23,000 --> 00:31:25,868 Now the engineers need to focus on the experience 534 00:31:26,033 --> 00:31:26,968 inside the stadium. 535 00:31:35,701 --> 00:31:39,601 Engineers in Liverpool are building a huge new stadium for 536 00:31:39,767 --> 00:31:41,267 the Everton Football Club. 537 00:31:42,667 --> 00:31:44,567 The stadium's designers want to recreate 538 00:31:44,734 --> 00:31:45,901 the electric atmosphere 539 00:31:46,067 --> 00:31:48,467 of the club's old site, Goodison Park. 540 00:31:50,868 --> 00:31:53,901 The bits that everybody loves about Goodison are what we want 541 00:31:54,067 --> 00:31:56,267 to bring to Bramley-Moore, 542 00:31:56,434 --> 00:32:00,367 about recreating our fortress that is Goodison and making it 543 00:32:00,534 --> 00:32:03,467 a really intimidating place for the away team to come. 544 00:32:03,634 --> 00:32:07,000 The designer's solution is to make the stands the steepest 545 00:32:07,167 --> 00:32:08,767 of any stadium in the country. 546 00:32:10,901 --> 00:32:14,400 To do that, the rise of the steps must increase 547 00:32:14,567 --> 00:32:16,167 the higher they get. 548 00:32:16,334 --> 00:32:19,000 You can just sort of perceive that kind of gentle curve as 549 00:32:19,167 --> 00:32:22,367 you get steeper and steeper up the stadium stand, 550 00:32:22,534 --> 00:32:25,501 by the time you get up to the back of the tier, 551 00:32:25,667 --> 00:32:27,300 you've got quite a big step. 552 00:32:27,467 --> 00:32:29,267 And so the angle at that point 553 00:32:29,434 --> 00:32:31,801 is the steepest part of the whole stadium. 554 00:32:31,968 --> 00:32:33,968 So we've sort of maxed out the regulations in order to 555 00:32:34,133 --> 00:32:37,000 kind of create that particularly imposing atmosphere. 556 00:32:42,300 --> 00:32:45,567 The crews build the terraces from thousands of differently 557 00:32:45,734 --> 00:32:48,167 sized prefabricated concrete components. 558 00:32:54,167 --> 00:32:57,534 They must install each one into its correct place. 559 00:33:00,067 --> 00:33:02,300 It's painstaking work 560 00:33:02,467 --> 00:33:06,067 that takes the team 12 months to complete. 561 00:33:08,501 --> 00:33:13,000 Next, an army of seat fitters descends on the stands 562 00:33:13,167 --> 00:33:16,367 and installs the stadium's 52,000 seats. 563 00:33:27,767 --> 00:33:30,467 The steep, curved stands and the seating close to 564 00:33:30,634 --> 00:33:34,100 the pitch is a key step to creating the intense atmosphere 565 00:33:34,267 --> 00:33:35,567 the fans crave. 566 00:33:37,100 --> 00:33:40,567 The steepness element formed a big part of the design around 567 00:33:40,734 --> 00:33:42,167 creating that fortress. 568 00:33:42,334 --> 00:33:45,000 You can see it from the front row when you look up. 569 00:33:47,467 --> 00:33:49,601 It certainly feels steep from down here, and I'm sure 570 00:33:49,767 --> 00:33:53,000 it's not for the faint-hearted to be on that back row. 571 00:33:53,167 --> 00:33:54,501 But yeah, there's no bad seat in the house, 572 00:33:54,667 --> 00:33:55,968 so anywhere anyone sits in the ground, 573 00:33:56,133 --> 00:33:57,200 they've got a great view of the game. 574 00:34:04,467 --> 00:34:07,467 The stadium's architect, Dan Meis, builds in another 575 00:34:07,634 --> 00:34:10,767 feature to maintain its pressure-cooker atmosphere. 576 00:34:13,000 --> 00:34:14,901 [Dan] What we had talked about from the very beginning 577 00:34:15,067 --> 00:34:16,400 was this cauldron of energy. 578 00:34:16,567 --> 00:34:19,000 So we knew that we needed to keep the roof as tight as 579 00:34:19,167 --> 00:34:22,567 we could on top of the stands that were right on top of 580 00:34:22,734 --> 00:34:24,501 the pitch, because that was going to keep all the sound 581 00:34:24,667 --> 00:34:26,167 in the building. 582 00:34:26,334 --> 00:34:30,167 Dan designs the stadium's roof as a giant curve that reflects 583 00:34:30,334 --> 00:34:33,534 the sounds the fans make back onto the stands. 584 00:34:36,000 --> 00:34:40,567 The design consists of 872 perforated panels 585 00:34:40,734 --> 00:34:42,567 that vary in angle across the structure. 586 00:34:47,701 --> 00:34:50,267 To install them, the construction crew must use 587 00:34:50,434 --> 00:34:51,667 a special crane attachment. 588 00:34:56,901 --> 00:34:58,400 On the end of the crane hook, 589 00:34:58,567 --> 00:35:02,067 the team will hang a long steel beam 590 00:35:02,234 --> 00:35:06,501 with a posable hydraulic mount that clamps onto anchors points 591 00:35:06,667 --> 00:35:07,667 on the cladding panel 592 00:35:09,501 --> 00:35:11,701 and tilts it to its final orientation. 593 00:35:13,767 --> 00:35:17,000 At the opposite end, a sliding counterweight runs 594 00:35:17,167 --> 00:35:18,534 along tracks on the beam. 595 00:35:19,300 --> 00:35:23,667 It balances the load and allows the crew to install each panel 596 00:35:23,834 --> 00:35:26,300 in a single controlled lift. 597 00:35:26,467 --> 00:35:29,467 Driven by this mechanism, the crane repeats the same 598 00:35:29,634 --> 00:35:33,367 precise motion to slot the panels into place 599 00:35:33,534 --> 00:35:34,501 one after another. 600 00:35:43,067 --> 00:35:45,868 The first truckloads of cladding arrive on site 601 00:35:46,033 --> 00:35:49,100 just 18 months before the first game of the season. 602 00:35:53,567 --> 00:35:56,601 Each large panel weighs 550 pounds. 603 00:35:57,868 --> 00:36:00,567 Their flat shape makes them difficult to control 604 00:36:00,734 --> 00:36:03,334 in the strong winds that buffet Liverpool's docks. 605 00:36:05,801 --> 00:36:08,501 Liverpool's quite a windy city anyway, but being right down 606 00:36:08,667 --> 00:36:11,100 on the kind of front face of it, you are really exposed, 607 00:36:11,267 --> 00:36:13,367 so there's no perfect time for doing these lifts. 608 00:36:13,534 --> 00:36:16,100 And we need to get playing in here as soon as possible. 609 00:36:19,767 --> 00:36:21,701 The crane team attaches the first panel, 610 00:36:25,000 --> 00:36:26,667 and adjusts it to the correct angle. 611 00:36:29,901 --> 00:36:32,100 The crane begins the lift 612 00:36:34,567 --> 00:36:37,567 130 feet up towards the stadium roof. 613 00:36:42,367 --> 00:36:45,000 Crane slingers hold on to trailing tag lines 614 00:36:45,167 --> 00:36:46,467 to prevent a collision 615 00:36:48,467 --> 00:36:50,434 and help guide the panel into place. 616 00:36:52,868 --> 00:36:55,901 Over the next six months, the cladding team installs 617 00:36:56,067 --> 00:36:59,968 a further 871 of these panels into place using 618 00:37:00,200 --> 00:37:01,601 their innovative robotic arm. 619 00:37:07,267 --> 00:37:09,767 It completes the challenge just one year 620 00:37:09,934 --> 00:37:12,901 before the stadium's first game. 621 00:37:13,067 --> 00:37:15,367 86,000 square feet of 622 00:37:15,534 --> 00:37:17,868 perforated aluminum wrap around the stadium, 623 00:37:20,000 --> 00:37:23,767 ready to create the cauldron of noise for the first match. 624 00:37:23,934 --> 00:37:26,100 [audience roaring] 625 00:37:36,000 --> 00:37:39,400 Engineers in Liverpool are racing to complete a brand-new 626 00:37:39,567 --> 00:37:42,567 soccer stadium in time for the opening game of the season. 627 00:37:48,300 --> 00:37:50,267 A busy schedule means this site 628 00:37:50,434 --> 00:37:52,534 will often host two games a week. 629 00:37:55,000 --> 00:37:57,868 A 90-minute soccer match inflicts a lot of damage 630 00:37:58,033 --> 00:38:00,300 on a natural grass field. 631 00:38:02,767 --> 00:38:05,167 It's critical that the pitch recovers in time 632 00:38:05,334 --> 00:38:06,267 for the next game. 633 00:38:11,801 --> 00:38:14,534 Head groundsman Jon Howell has a solution. 634 00:38:17,000 --> 00:38:20,467 So, this is a small intersection of what the pitch 635 00:38:20,634 --> 00:38:22,100 would look like underneath. 636 00:38:22,267 --> 00:38:25,667 These tough plastic fibers sit between the organic blades of 637 00:38:25,834 --> 00:38:27,367 grass to knit them together. 638 00:38:28,901 --> 00:38:31,167 [Jon] They reinforce the pitch on a sand-based pitch, 639 00:38:31,334 --> 00:38:35,467 and then we grow the grass in and around the roots attached 640 00:38:35,634 --> 00:38:38,767 to the base of the stitching, and it just holds it together. 641 00:38:42,467 --> 00:38:44,300 The challenge for John and his team 642 00:38:44,467 --> 00:38:46,200 is to turf and stitch more 643 00:38:46,367 --> 00:38:49,367 than 75,000 square feet of playing surface. 644 00:38:51,667 --> 00:38:54,200 Every stitch must be in the right place, 645 00:38:54,367 --> 00:38:56,000 because a gap creates weak points. 646 00:38:59,701 --> 00:39:03,567 The solution is a giant mobile stitching rig. 647 00:39:06,000 --> 00:39:10,167 This machine unspools over 37,000 miles of the plastic 648 00:39:10,334 --> 00:39:13,100 fiber and punches rows of it into to the ground 649 00:39:13,267 --> 00:39:14,567 two inches apart. 650 00:39:19,467 --> 00:39:22,200 After the automated rig is stitched the entire surface, 651 00:39:23,868 --> 00:39:26,400 the organic grass grows through the fibers. 652 00:39:28,067 --> 00:39:31,701 And John has a feel that looks and feels real, but is strong 653 00:39:31,868 --> 00:39:33,467 enough to withstand the punishment 654 00:39:33,634 --> 00:39:34,968 of an entire soccer season. 655 00:39:39,067 --> 00:39:41,167 But the pitch still needs light, heat, and water 656 00:39:41,334 --> 00:39:42,567 to grow quickly. 657 00:39:44,667 --> 00:39:48,167 Liverpool receives plenty of rain, but light and heat 658 00:39:48,334 --> 00:39:49,367 are lacking. 659 00:39:51,167 --> 00:39:52,567 [Jon] New stadiums, they're all unbelievable. 660 00:39:53,767 --> 00:39:56,400 But as a groundsman point of view, 661 00:39:56,567 --> 00:39:58,000 they're not great for growing grass. 662 00:39:58,167 --> 00:39:59,467 We're not going to get much sunlight. 663 00:39:59,634 --> 00:40:01,667 We've had next to nothing in the south. 664 00:40:03,167 --> 00:40:05,200 The north-south orientation of the stadium 665 00:40:06,868 --> 00:40:08,801 and its overhanging roof keeps 666 00:40:08,968 --> 00:40:11,667 the south end of the pitch in the shade 667 00:40:11,834 --> 00:40:14,667 and several degrees cooler than the north end. 668 00:40:14,834 --> 00:40:17,100 This slows grass growth dramatically. 669 00:40:18,367 --> 00:40:20,901 Going into match day, we know the eyes of the world 670 00:40:21,067 --> 00:40:23,501 are watching us now. It's going to be quite tight. 671 00:40:23,667 --> 00:40:25,067 Time's very limited with this weather. 672 00:40:27,400 --> 00:40:32,100 To solve this problem, engineers install 1,240 solar 673 00:40:32,267 --> 00:40:35,367 panels on the southern edge of the stadium roof. 674 00:40:37,801 --> 00:40:41,767 The electricity they generate powers 13 sun lamps to help 675 00:40:41,934 --> 00:40:43,400 the grass grow quickly. 676 00:40:45,868 --> 00:40:49,267 With these rigs, it's twofold. We've got pink LED lights. 677 00:40:49,434 --> 00:40:51,501 I find that's the best for the pitch, 678 00:40:51,667 --> 00:40:54,501 for the root developments and extra light. 679 00:40:54,667 --> 00:40:58,701 And then, the infrared heaters, as they're called. 680 00:40:58,868 --> 00:41:02,467 The team rotates the sun lamps to ensure every area of 681 00:41:02,634 --> 00:41:05,501 the pitch gets precisely the heat and light it needs. 682 00:41:06,968 --> 00:41:09,901 So the grass grows thick and strong for the opening 683 00:41:10,067 --> 00:41:11,667 match of the season. 684 00:41:15,367 --> 00:41:20,467 Engineers turned an unused dock into a solid foundation. 685 00:41:20,634 --> 00:41:24,601 Built upwards with brick at breakneck speed and engineered 686 00:41:24,767 --> 00:41:27,868 steel to create the ultimate match day experience. 687 00:41:30,000 --> 00:41:32,767 To construct a unique stadium 688 00:41:32,934 --> 00:41:35,167 that generations of fans will call home. 689 00:41:37,067 --> 00:41:39,767 It is a legacy to the team that made it. 690 00:41:41,501 --> 00:41:44,167 The stands finally begin to fill with fans 691 00:41:44,334 --> 00:41:45,601 for the first game. 692 00:41:45,767 --> 00:41:50,367 And this historic club begins an exciting new chapter. 693 00:41:50,534 --> 00:41:52,567 I think it'll be quite emotional, actually, 694 00:41:52,734 --> 00:41:55,367 to see 52,000 people in the stands. 695 00:41:55,534 --> 00:41:57,000 Going to be amazing! 62412

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